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Invacare ® FDX ® Series SERVICE MANUAL

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1. e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolt 4 out of the guide Pay attention to the bushings 3 117 SERVICE MANUAL Invacare FDX Series e Swing the tilt lever arm 1 forwards e Remove the retaining rings 1 from the front bolt 4 of the lifter actuator 2 with the spring ring pliers e Pull the bolt out of the guide with a pair of bent nose pliers until the bolt almost touches the tilt actuator 5 Pay attention to the bushings 3 118 Invacare FDX Series SERVICE MANUAL e Lift the tilt actuator 5 up a little e Pull the bolt 4 of the lifter actuator under the tilt actuator and out of the guide 2 e Remove the retaining rings 1 from the rear bolt 3 of the lifter actuator 2 with the spring ring pliers e Push the bolt out of the guides e Remove the actuator from the lifter module Installing the lifter actuator e Assemble all parts in reverse order e Perform a function test 119 SERVICE MANUAL Invacare FDX Series 8 13 3 Seat frame 8 13 3 1 Adjusting the seat width Note GD The seat width can be adjusted in stages between 38 and 53 cm Please also observe the following chapter 8 13 3 2 on adjusting the seat depth A Requirements dd e 4mm Allen key e Remove the seat cushion e Remove the cover plates 1 e Release the two Allen screws 6 on the crossbar at the rear and remove them e Release
2. CAUTION Danger of burns from hot surfaces on the motor e Allow the motors to cool down before commencing work on them ATTENTION Injury hazard and danger of damage to vehicle due to improper or incomplete maintenance work e Use only undamaged tools in good condition e Some moving parts are mounted in sockets with PTFE coating Teflon Never grease these sockets Never use normal nuts instead of self locking nuts Always use correctly dimensioned washers and spacers When reassembling always replace any cable ties which were cut during dismantling After completing your work before renewed start up of the mobility device check all connections for tight fitting e After completing your work before renewed start up of the mobility device check all parts for correct locking e Only operate the vehicle with the approved tyre pressures see technical data e Check all electrical components for correct function Please note that incorrect polarity can result in damage to the electronic e Always carry out a trial run at the end of your work CAUTION Danger of injury and damage to property if the maximum speed reduction ona wheelchair with a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is raised e Test the maximum speed reduction for correct function after any maintenance work or modifications to the wheelchair Note
3. e Loosen and remove the screw 6 the associated washers 5 and the nuts 4 in front of the behind the gripper clamp 3 with a 4 mm Allen key and a 10 mm socket wrench e Loosen and remove the screw 8 the associated washers 7 in the lower part of the harness belt 1 with a 4 mm Allen key and a 10 mm socket wrench 172 Invacare FDX Series SERVICE MANUAL Note GD Another nut is used between the washers as a spacer so that the belt bracket can move freely e Replace the harness belt 1 Installing the harness belt e Assemble the parts in reverse order 173 SERVICE MANUAL Invacare FDX Series 9 3 Replacing seat belts Modulite seat 9 3 1 Installation on the backrest mounting bracket simple backrest 1A Requirements EU e 13 mm Socket spanner e 5mm Allen key e The seat belts are attached via the drill hole 1 at the top right e The installation of seat belts is described in chapter 9 1 174 Invacare FDX Series SERVICE MANUAL 9 3 2 Installation on the backrest mounting bracket adjustable seat VV Requirements We 5mm Allen key e Loosen the screw 1 with a 5 mm Allen key e Remove the screw 1 the corresponding washer 2 and the seat belt and belt winder 3 from the backrest mounting bracket 4 e Replace the safety belt e Refit the parts in the reverse order 175 SERVICE MANUAL Invacare FDX Series 9 3 3 Installation on the seat frame profile adjustable
4. The driving programs for electric wheelchairs are continually updated and improved by Invacare For this reason you should check whether the version number is still up to date each time a wheelchair comes in for repairs and also during regular inspections lf a newer version is available the driving program must be updated The procedure for updating the driving program is described in the user manual of the Wizard software Note The electronic system is supplied with a standard drive program If the driving program has been customised you have to perform this customisation again after installing the new driving program This also applies to the customer specific options of the seat setting for ACS2 remotes which are activated ex works WARNING Every alteration to the drive program can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive program must only be carried out by trained Invacare dealers e nvacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs Pre requisites e Dynamic Wizard software e User manual for the Wizard software e For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessary programming cables see the user manual of the Wizard software You find the latest version of the user ma
5. e Detach all cables from the electronic modules which run from the seat to the chassis e Place the cables so that they do not get in the way when you remove the seat Invacare FDX Series SERVICE MANUAL e Insert a suitable wooden block 2 between the seat 1 and the chassis 3 This will prevent the seat from falling down when you loosen and remove the screws WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques e Use the 6 mm Allen key to loosen and remove the screws 4 on both sides in the front at the same time e Hold the seat securely and loosen the rear hexagon socket head screw 5 on both sides with a 6mm Allen key at the same time e Lift the seat off 103 SERVICE MANUAL Invacare FDX Series sinc the seat frame A front seat frame B rear seat frame e Use a6 mm Allen key to loosen the hexagon socket head screws 2 e Pull the seat frame 1 up and off Installing the seat and seat frame e Assemble all parts in reverse order e When installing the seat pay attention to its heavy weight e When installing the seat pay attention to the adjustment settings of the seat tilt e Tighten the screws to a torque of 25 Nm e Check all functions of the vehicle and go for a test drive 104 Invacare FDX Series SERVICE MANUAL 8 13 2 Replacing the tilt module lifter module 8 13 2 1 Replacing the tilt module
6. 8 13 2 4 Replacing the lifter actuator i 114 Note This chapter only describes how to replace the lifter actuator To replace the complete lifter module please follow the procedures explained in chapter 8 13 2 2 Possible methods The lifter actuator is very easy to replace when the lifter is in a raised position It is a little more complicated to replace when the lifter is in a lowered position and cannot be raised due to a fault The individual work steps for both methods are described hereafter To replace the raised lifter please follow the procedures explained in section header Method 1 uninstalling the lifter actuator with the lifter raised e To replace the lowered lifter please follow the procedures explained in section header Method 2 uninstalling the lifter actuator with the lifter lowered Method 1 uninstalling the lifter actuator with the lifter raised WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Use proper lifting techniques e Carefully secure the seat before removing the actuator Requirements e Spring ring pliers e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cables and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects th
7. See chapters 8 11 1 running movable or bent replace and 8 11 3 transmission if defective None Parts lost Reattach parts once found Batteries not None Fuse burnt out Check cabling See chapters 8 4 5 being charged cable defective and replace fuse and 8 4 4 SERVICE MANUAL PROBLEM Short charging period Mobility aid runs too slowly Actuator does not react None None POSSIBLE CAUSE Batteries defective OTHER SYMPTOMS LEDs blinking on charging unit Charging unit defective One of the batteries could be defective Batteries defective Lighting actuator module defective Remote shows blinking E or blink code 2 Status diode on lighting actuat or module does not go out even if the remote has been switched off or disconnected Cable disconnected or damaged Electrical adjusting motor defective Invacare FDX Series SOLUTION Replace batteries Replace charging unit Replace batteries DOCUMENTATION See chapter 8 4 1 See charging unit operating manual see chapter 8 4 1 Remote Replace remote see chapter 8 2 1 defective Replace batteries See chapter 8 4 1 Replace lighting actuator module Safeguard cable connection replace cable if necessary Check adjusting motor see chapter 8 2 2 see chapter 8 4 5 Remote Replace remote see chapter 8 2 1 defective Only applies to remote SD24 All remotes except SD24 28
8. secure fit replace if necessary l e Check the version of Update the See chapter 8 3 Orive program the program in the software if a i driving electronic newer version Is available a B T B E B E 23 SERVICE MANUAL Invacare FDX Series 24 Operational faults The various electronic modules can be fitted in connection with differing remotes in the mobility aid Rectification of operational faults is dependent on the electronic module fitted The electronic modules used are described in Chapter 4 2 Note The tables for rectification of operational faults listed in the following chapters are only an excerpt from the original manufacturer s manuals You can obtain the original manuals from Invacare If you have problems with the mobility aid please proceed as follows e First assess the possible cause of the problem using the following table e Check the remote status display Evaluate the error code e Carry out the necessary checks and repairs as recommended in the following table Invacare FDX Series 6 1 Drive fault diagnosis PROBLEM The remote status display illuminates normally and displays blink code 5 6 Remote status display does not illuminate Mobility aid will not start Remote status display blinking None None None None Mobility aid judders in drive mode Mobility aid pulls to left or right Error message does not go out Moto
9. Invacare FDX Series SERVICE MANUAL 6 2 REM remotes Error codes and diagnostic codes i Note GD The following table is applicable to remotes G90A REM A REM B und REM 550 which are connected to electronic modules ACS2 PMB70 ACS2 PMB70L ACS2 PMB90LG The drive electronic can automatically rectify some faults In this case the status display will stop blinking Switch the remote on and off again several times Wait around 5 seconds each time before switching the remote on again If this does not rectify the fault determine the cause using the blink codes from the following table BLINK CODE POSSIBLE CAUSE SOLUTION DOCUMENTATION Module defective Replace defective module See chapter 8 2 2 Accessory error e g short Check accessory See chapter 8 4 5 circuit in adjusting motor connections check accessory Lifter too high or too low If the lifter is raised lower it See operating manual seat not at driving height slowly until the status display stops blinking If the lifter is too low raise it slowly until the status display stops blinking Only drive when the seat is at driving height Fault on left hand motor Check connection plug see chapters 8 4 5 M2 Connection check motor and 7 1 loose defective or motor defective Fault on right hand motor Check connection plug See chapters 8 4 5 M1 Connection check motor and 7 1 loose defective or motor defective Fault orake fault on left Check conne
10. 0 22 57 95 01 norway invacare com island invacare com www invacare no 31 0 318 69 57 57 31 0 318 69 57 58 nederland invacare com csede invacare com www invacare nl 351 225 10 59 46 351 225 10 59 47 351 225 10 57 39 portugal invacare com www invacare pt 46 0 8 761 70 90 46 0 8 761 81 08 sweden invacare com finland invacare com www invacare se 46 0 31 86 36 00 46 0 31 86 36 06 ginvacare invacare com 46 0 418 2 85 40 46 0 418 1 80 89 linvacare invacare com 46 0 491 1 01 40 46 0 491 1 01 80 oinvacare invacare com 49 0 5731 75 45 40 49 0 5731 75 45 41 edo invacare com www invacare de SERVICE MANUAL SERVICE MANUAL Invacare FDX Series Table of contents Chapter Page 1 INTRODUCTION 8 1 1 General information 8 1 2 Notes on transport 8 1 3 Definition and representation of information and safety information in this manual 9 1 4 Hazard symbols and symbols used 10 1 5 Images in this manual 11 2 SAFETY AND FITTING INSTRUCTIONS 12 2 1 Before any inspection or repair work 12 2 2 Personal safety equipment 12 2 3 General safety information and information about fitting removal 12 3 TIGHTENING TORQUES 14 4 ARRANGEMENT OF SUB ASSEMBLIES AND COMPONENTS 15 4 1 Overview 15 4 2 Electronic modules 16 4 2 1 ACS2 PMB70 ACS2 PMB70L electronic module 17 4 2 2 ACS2 PMAQOL electronic module 17 4 2 3 Actuator module ACT 17 4 2 3 1 Actuator module ACT2 17 4 2 3 2 Actuator module ACT 4 18 4 2 4 Li
11. decrease voltage SOLUTION DOCUMENTATION oe Motors stop None High motor Leave mobility aid loading causes switched on and electronic allow electronic module to module to work and do not start again decrease Charge batteries voltage overnight with mobility aid switched on None Fuse burnt out Check cabling See chapters 8 4 5 and replace fuse and 8 4 4 None Motor defective Check carbon See chapter 8 11 4 brushes and replace if necessary Measure internal see chapters 7 1 resistance of and 8 11 1 motor replace motor if defective None Electronic Replacing the see chapter 8 2 2 module electronic module defective Motors lose None Bad Switch mobility see chapter 8 4 5 power during connections aid off wait 10 journey seconds switch mobility aid on again Check all cabling Motor judders None Carbon brushes Check carbon See chapter 8 11 4 or runs worn brushes and irregularly or replace if only one motor necessary a Clutch es Replace clutch See chapter 8 11 3 defective Bearing Replacing the see chapter 8 11 1 defective motor Collector Measure internal see chapters 7 1 defective resistance of and 8 11 1 motor replace motor if defective Fuse burnt out Check cabling see chapters 8 4 5 and replace fuse and 8 4 4 Batteries Replace batteries See chapter 8 4 1 defective Motors do not None Bad Check all cabling See chapter 8 4 5 run connectio
12. pushing e Replace motor if e Check coupling necessary mechanism e Tighten screws nuts adjust or replace if necessary e Motor brake check e a the motor See chapter 7 2 a e Check welding e Tighten replace if See chapter 8 14 amp seams locking necessary the User Guide devices screws and foot plates e Check cable e Replace cable if See chapter 8 14 amp ra Aaa e Check contacts necessary ihe ey if available e Check functions re abe toe e Check cable e f necessary See chapter 8 6 padi A e Check function replace light or cable e Check battery box e Replace if damage A atiarlec e Check batteries for e Replace batteries See chapter 8 4 1 damage if necessary and 8 4 3 e Check battery e Charge batteries ro voltage e Check battery e Charge batteries See instruction voltage manual e Check contacts and e Clean contacts See the safety 7 Legrests terminal clamps and terminal notes in chapter clamps 8 4 1 and 8 4 3 for information on correctly handling batteries 22 Invacare FDX Series SERVICE MANUAL Component Check for Measures Remarks e Remote status e Analyse the error electronic modile e Fixations e Tighten fixations replace if necessary e Cables and plug in e Check all cables connections and plug in connections for secure fit replace if necessary e Joystick function Replace joystick if necessary Replace remote if necessary e Power supply Check all cables and plug in connections for
13. 13mm socket wrenches two of them e Torque wrench 0 30 Nm or similar Removing a rear fixation ring e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Use both 13 mm socket wrenches to loosen and remove both screws 1 e Pull the fixation ring 2 backwards out of the bracket Installing a rear fixation ring e Assemble all parts in reverse order e Tighten the screws 1 to a torque of 25 Nm e Check all functions of the vehicle and go for a test drive 170 Invacare FDX Series SERVICE MANUAL 9 Installing accessories 9 1 Replacing the restraining belt VA Requirements EAF e 10 mm socket wrench e 4mm Allen key Uninstalling the restraining belt e Loosen the screw 3 and the corresponding nut not shown in the illustration with a 4 mm Allen key and a 10 mm socket wrench e Remove the nut including the washer Remove the screw together with the restraining belt and the washer 2 and also the washer behind it Note D Another nut is used between the washers as a spacer so that the belt bracket can move freely e Replace the restraining belt 1 Installing the restraining belt e Assemble the parts in reverse order 171 SERVICE MANUAL Invacare FDX Series 9 2 Replacing the harness belt VA Requirements i e 10mm socket wrench e 4mm Allen key Uninstalling the harness belt e Remove the protective cap 2
14. Fondettes contactfr invacare com France WWW www invacare fr GB Invacare Lid Customer services 44 0 1656 77 62 22 GB Pencoed Technology Park Fax Customer services 44 0 1656 77 62 20 Pencoed uk invacare com Bridgend CF35 5HZ WWW www invacare co uk United Kingdom Cl Invacare Mecc San s r l 39 0445 38 00 59 iD Via dei Pini 62 Fax 39 0445 38 00 34 36016 Thiene VI italia invacare com Italia WWW www invacare it Invacare FDX Series CP O EN Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Rd Swords County Dublin Ireland Invacare AS Grensesvingen 9 Postboks 6230 Etterstad N 0603 Oslo Norge Invacare B V Celsiusstraat 46 NL 6716 BZ Ede Nederland Invacare Lda Rua Estrada Velha 949 P 4465 784 Le a do Balio Portugal terf rs ljare Invacare AB Fagerstagatan 9 S 163 91 Spanga Sverige Tillverkare Invacare Deutschland GmbH KleiststraBe 49 D 32457 Porta Wesifalica Deutschland Eastern European Distributor european Organisation EDO countries KleiststraBe 49 D 32457 Porta Westfalica Deutschland Fax WWW Kundeservice Fax Kundeservice WWW Kundtjanst Fax Kundtjanst WWW MOLNDAL Fax LANDSKRONA gt Fax OSKARSHAMN Fax Fax WWW 353 18 10 70 84 353 18 10 70 85 ireland invacare com www invacare ie 47 0 22 57 95 00 47
15. In the area denoted by the 2 there is an adjustment screw that can only be reached when the footplate is swivelled upwards e Use the 1 64 Allen key to adjust the angle of the footplate to the needs of the user with this screw 133 SERVICE MANUAL Invacare FDX Series 8 15 Back unit 8 15 1 Replacing the standard back UA Requirements e 5mm Allen key e Socket spanner 13 mm mo ga th Pa war ie als Te a kn S ie i v aia ie a i in al iP a a i A P T W Dismantling the back unit e Remove the back cushion e Loosen and remove the handwheels 3 and the Allen screws 4 including the washers on the left and right side of the mobility aid e Carefully remove the rear pipe 1 of the back bracket 2 e lf the backrest holders also need to be replaced undo and remove the Allen screws 5 including the washers on the left hand and right hand side of the chair Refitting the back unit e Refit the parts in reverse order e To conclude check all the mobility aid functions 134 Invacare FDX Series SERVICE MANUAL 8 15 2 Adjusting the belt back The belt back can be individually adapted to the back shape of the user e Pull apart the front and back of the back cushion 1 and remove it Front and back of the back cushion is held together by Velcro e Open Velcro straps of the back straps 2 and set it to the desired length e Refit the back cushion and fasten with Velc
16. Mark all current settings for the mobility aid seat armrests backrest etc and the associated cable connecting plugs before dismantling This makes reassembly easier All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation To release the connecting plugs the safety devices must be pressed in When reassembling ensure that these safety devices are correctly engaged WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle e Changes to the drive program may only be carried out by trained Invacare specialist dealers e nvacare supplies all mobility aids with a standard drive program ex works Invacare can only give a warranty for safe vehicle driving behaviour especially tipping stability for this standard drive program 13 SERVICE MANUAL Invacare FDX Series Tightening torques The tightening torques stated in the following list are based on the thread diameter for the nuts and bolts for which no specific values have been determined All values assume dry and de greased threads Tightening torque 3Nm 6Nm 10Nm 25Nm 49Nm 80Nm 120 Nm 180 Nm in Nm 10 CAUTION Damage can be caused to the mobility device due to improperly tightened screws nuts or plastic connections e Always tighten screws nuts etc to the stated tightening torque e Only tighten screws or nuts w
17. Replacing the motor gearbox unit 91 8 11 2 Replacing or rotating the motor gearbox unit sealing ring 93 8 11 3 Replacing the motor gearbox coupling 94 8 11 4 Replacing the carbon brushes 96 8 11 5 Fitting the clutch rotary knob SSD motor 98 8 11 6 Running the motor in 99 8 12 Replacing the motor gearbox fixation and rear wheel cantilever arm 100 8 13 Seat adjustment standard 102 8 13 1 Seat seat frame without lifter 102 8 13 2 Replacing the tilt module lifter module 105 8 13 2 1 Replacing the tilt module without lifter 105 8 13 2 2 Replacing the lifter tilt module 108 8 13 2 3 Replacing the tilt actuator 112 8 13 2 4 Replacing the lifter actuator 114 8 13 3 Seat frame 120 8 13 3 1 Adjusting the seat width 120 8 13 3 2 Adjusting the seat depth 122 8 14 Centre mounted legrest electric amp manual 126 8 14 1 Replacing the manually operated centre mounted legrest 126 8 14 2 Replacing the electrically operated centre mounted legrest 127 8 14 3 Replacing the electrically operated centre mounted legrest LNX Modulite seat 129 8 14 4 Replacing an electric legrest actuator 130 8 14 5 Replacing the calf plate on the centre mounted legrest electric amp manual 132 8 14 6 Replacing the foot plate on the centre mounted legrest electric amp manual 133 8 15 Back unit 134 8 15 1 Replacing the standard back 134 8 15 2 Adjusting the belt back 135 8 15 3 Replacing the EasyAdapt back 136 8 15 4 Replacing adjusting the universal b
18. and remove both bushes 7 including the lamp protector 2 Installing the tail lamp e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions 19 76 SERVICE MANUAL Invacare FDX Series 8 6 14 Replacing the tail lamp bracket conventional lighting system until 08 2014 VA Requirements Si e 3mm Allen key Uninstalling the head lamp bracket e Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Uninstall the complete tail lamp assembly as described in chapter 8 6 12 e Use the 3 mm Allen key to loosen and remove both screws 2 e Replace the lamp bracket 1 Installing the head lamp bracket e Assemble all parts again in reverse order e Check all vehicle functions Invacare FDX Series SERVICE MANUAL 8 6 15 Replacing the tail lamp bracket conventional lighting system starting 08 2014 Ni Requirements cin e 3mm Allen key 1a Uninstalling the head lamp bracket e Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Uninstall the complete tail lamp assembly as described in chapter 8 6 13 e Use the 3 mm Allen key to loosen and remove both screws 2 e Replace the lamp bracket 1 Installing the head lamp bracket e Assemble all parts again in reverse order e Check all vehicle functions 17 SERVICE MANUAL Invacare FDX Series 8 6 16 Replacing
19. chapter 8 18 4 1 VA Requirements IU e 3mm Allen key e 5mm Allen key e 13mm Open ended spanner The screw position for the backrest width refer to the table ee ae po UB 480mm gt 30m 166 Invacare FDX Series SERVICE MANUAL e Remove the backrest cushion e Loosen the straps of the sling backrest or remove the Flex3 backrest e Loosen and remove both screws 5 of the actuator fixation bracket e Remove the cover of the actuator fixation bracket e Loosen and remove the screws and nuts 2 4 on the upper and lower actuator fixation bracket on both sides e Adjust the backrest fixation 6 for the new backrest width according to the table on page 166 e Insert the screws 2 through the cover of the actuator fixation bracket and the corresponding holes of the backrest fixation to the actuator fixation e Fasten these with the nuts 4 e Reposition the cover of the actuator fixation bracket e Insert and tighten the screws 5 again e Adjust the straps of the sling backrest to the new width or install the adjusted Flex 3 backrest e Install the backrest cushion e Perform a function check of the chair 167 SERVICE MANUAL Invacare FDX Series 8 18 4 4 Adjusting the Flex3 backrest UA Requirements EU e Phillips screwdriver e 5mm Allen key Remove the front lateral plates 2 and 4 from the backrest 1 by loosening and removing the five hexagon socket head screws 3 e Remove bo
20. clamp 3 with a 5 mm Allen key and a 13 mm socket wrench e Remove the protective cap 9 e Loosen and remove the screw 8 the associated washers 7 and the nuts in the lower part of the harness belt 1 with a 5 mm Allen key and a 13 mm socket wrench 179 SERVICE MANUAL Invacare FDX Series Note GD Another nut is used between the washers as a spacer so that the belt bracket can move freely e Replace the harness belt 1 Installing the harness belt e Assemble the parts in reverse order 180 Invacare FDX Series SERVICE MANUAL 9 4 DAHL Docking Station A CAUTION Danger of crushing The mobility device is very heavy Injury hazard to hands and feet Use proper lifting techniques Injury hazard caused by uncontrolled movement of the mobility device Switch the power supply off ON OFF key Engage the drive Position the mobility device on it s side and secure the position so it does not turn over AS Requirements ANF e 6mm Allen key e high strength screw blocker system e g Loctite 270 For unprepared wheelchair additional e 4mm Allen key e 5mm Allen key 181 SERVICE MANUAL Invacare FDX Series Note GD Depending on the vehicle several spacers 2 may be required in addition to the safety plate 3 Please refer to the documentation provided by DAHL see also www dahlengineering dk for information on whether and how many spacers are required Note The countersunk screw 4 mater
21. have come into contact with acid with lots of water Disposing of dead or damaged batteries correctly Dead or damaged batteries can be given back to your dealer or directly to Invacare Replacing the main fuse Note To replace the fuse the battery cable with the fuse attached to it must be replaced e Replace the battery cables as described in chapter 8 4 2 55 SERVICE MANUAL Invacare FDX Series 8 4 5 Checking the cables 1A Requirements zH e Side cutting pliers e Cable ties e Remove the covers disconnect the battery plug connections and pull the batteries out of the battery compartment as described in chapter 8 4 1 e Check the fuse cable 1 the battery cable 2 and the battery connections 3 for visible damage and pinches e Replace damaged cables as described in chapter 8 4 2 Note a The positions of the plugs are described in chapter 4 2 56 Invacare FDX Series SERVICE MANUAL e Check all cables for visible damage and crushing Replace damaged cables e Pull on each plug 1 carefully The plug must not come out of the socket e Ifa plug is loose apply slight pressure to push the plug into the socket The plug must snap in place securely e Check whether the connector is fitted firmly If not repeat the previous step e Assemble the parts in reverse order e Check all functions of the vehicle and go for a test drive 57 SERVICE MANUAL Invacare FDX Series 8 5 Replacing
22. incl the washers with a 5 mm Allen key e Lift the module of the seat angle adjustment 1 from the adapter and replace it e Reassembly takes place in the reverse order Note Make sure that all screws washers and nuts are reassembled in the correct order and securely tightened during assembly e To complete check all seat tilting function 157 SERVICE MANUAL Invacare FDX Series 8 17 5 Replacing the backrest actuator Dismantling the backrest actuator e Pull the cable off directly where it is connected to the actuator 1 e Detach the bracket of the actuator at the top and bottom to do this slide the bolts 3 to the side using the lever 4 and tilt the actuator 1 out of the backrest clamp 2 e Replace actuator Refitting the backrest actuator e Assemble the parts in the reverse order 158 Invacare FDX Series 8 18 Backrest Modulite 8 18 1 Replacing the standard backrest UA Requirements e 5mm Allen key Dismantling the backrest unit e Remove the backrest cushion e Loosen the fixation lever 2 of the backrest tube e Remove the backrest tube Refitting the backrest unit e Replace the parts in the reverse order SERVICE MANUAL Use the Allen key to loosen and remove the hexagon socket head screws 3 including the nuts and washers on the left and right side of the chair To conclude you should always carry out a trial run to test the vehicle functions 159 SERVI
23. remote together with its cable e Rotate the armrest upwards e Undo the two holding bolts 1 with a 4 mm Allen key e Replace the arm support Refitting the travelling armrest e Replace the parts in the reverse order e Tocomplete check all vehicle functions The new armrest will need to be adjusted to suit the user Please refer to the mobility device operating manual for detailed information 148 Invacare FDX Series SERVICE MANUAL 8 16 9 Retrofitting a travelling armrest GD NOTE The travelling armrest can only be retrofitted if the entire backrest is replaced since the torque support must be fitted with the correct guides Retrofitting the travelling armrest e Fit the backrest for the travelling armrest as described in chapter 8 15 3 e Fit the armrests as described in chapter 8 16 7 e Fit the arm supports as described in chapter 8 16 8 The new armrest will need to be adjusted to suit the user Please refer to the mobility device operating manual for detailed information 149 SERVICE MANUAL Invacare FDX Series 8 17 Seat adjustment Modulite 8 17 1 Seat seat frame Modulite without lifter 150 Note This chapter describes how to replace the seat frame on a wheelchair without a lifter or tilt module To replace a lifter or tilt module please follow the procedures explained in chapter 8 17 4 WARNING Danger of crushing The seat is very heavy Danger of injury to hands an
24. side of INVACARE If you have any problems or questions please contact Invacare Service Notes on transport If the mobility aid has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport Please attach a precise description of the fault Invacare FDX Series SERVICE MANUAL 1 3 gt BP D Definition and representation of information and safety information in this manual Different types of information and signal words are used throughout this manual HAZARD The signal word HAZARD refers to immediate hazards e The following lines in italics refer to actions which serve to avoid such hazards WARNING The signal word WARNING refers to possibly occurring hazards which can lead to death or serious injuries if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards ATTENTION The signal word ATTENTION refers to possibly occurring hazards which can lead to minor injuries and or material damage if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards CAUTION The signal word CAUTION refers to hazards which could lead to material damage if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards Note The signal word Note is used to denote general information which simplifies the han
25. standardised safety shoes during all work Eye protection It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly e Always wear eye protection when working on any defective or possibly defective batteries Safety gloves It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly e Always wear acid proof safety gloves when working on any defective or possibly defective batteries General safety information and information about fitting removal WARNING Danger of crushing Various components such as the drive unit batteries seat etc are very heavy This results in injury hazards to your hands e Please note the high weight of some components This applies especially to the removal of drive units batteries and the seat WARNING Injury hazard if the vehicle starts moving unintentionally during repair work e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges ATTENTION Fire and burn hazard due to electrical short circuit e The mobility device must be completely switched off before removal of voltage carrying components To do this remove the batteries e Avoid short circuiting the contacts when carrying out measurements on voltage carrying components Invacare FDX Series SERVICE MANUAL
26. the battery boxes Nii Requirements My 7 mm socket wrench 8 mm socket wrench 10 mm socket wrench 13 mm socket wrench 16 mm socket wrench 22 mm socket wrench 13 mm open ended wrench 3 mm Allen key 4 mm Allen key 5mm Allen key 6 mm Allen key Small flat screwdriver Torque wrench 5 30 Nm or similar Torque wrench 10 80 Nm or similar Side cutting pliers Cable ties Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the battery box e Remove the drive wheels as described in chapter 8 8 1 e Uninstall all plastic covers as described in chapter 8 1 e Remove all electronic modules that are fitted in the rear on the battery box as described in chapter 8 2 2 e Remove the seat including the seat frame as described in chapter 8 13 and 8 17 e Remove the batteries as described in chapter 8 4 1 e f necessary remove the conventional rear lighting system as described in chapters 8 6 10 and 8 6 14 e Remove the anti tipper wheels as described in chapter 8 10 e Remove the motor gearbox mounting including suspension as described in chapter 8 12 e Remove the fixation rings as described in chapter 8 19 e Replace the battery box Installing the battery box e Install the fixation rings as described in chapter 8 19 e Install the motor gearbox mounting including suspension as described in chapter 8 12 e Install the drive wheels as described in chapter 8 8 1 e Install the anti tipp
27. the fastening holes in front of the boreholes of the backrest hinge e Refit the two Allen screws 6 incl the washers and tighten the screws 184 Invacare FDX Series SERVICE MANUAL 9 6 Further accessories Note The installation instructions for additional accessories are available at your Invacare specialist supplier or directly from Invacare 185
28. the tail lamps completely LED lighting system Note GD Individual LEDs are not intended to be replaced The LEDs are replaced along with the complete bracket assembly This means that the complete red or yellow tail lamp is replaced VA Requirements EA e Phillips screwdriver size 1 Uninstalling the tail lamp e Remove the front rear and the applicable lateral cover as described in chapters 8 1 1 8 1 2 and 8 1 3 e Use a Phillips screwdriver to loosen and remove the screw 1 e Remove the transparent cover from the top side not visible in the illustration e Carefully bend both mounting brackets 2 apart e Push the tail lamp 3 including cable and plug out of the bracket Installing the tail lamp e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions 18 Invacare FDX Series SERVICE MANUAL 8 7 8 7 1 Vd A Rear wheels Replacing a rear wheel Requirements e Small flat screwdriver e 16mm socket wrench e Two oblong wooden blocks at least 14 x 14 x 30 cm WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Uninstalling a rear
29. without lifter Note GD This chapter describes how to replace the tilt module on a wheelchair without a lifter Similar tasks are described In the following chapters e Replacing the seat frame alone chapter 8 13 1 e Replacing a lifter tilt module chapter 8 13 2 2 e Replacing just the tilt actuator chapter 8 13 2 3 e Replacing just the lifter actuator chapter 8 13 2 4 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques gt Requirements e 13mm open ended wrench 4 mm Allen key 6 mm Allen key Side cutting pliers Cable ties F i ha E LF Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the tilt module e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame 105 SERVICE MANUAL Invacare FDX Series 106 e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free u
30. x 30 cm Removing the lateral cover Remove the drive wheel as described in chapter 8 8 1 Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 Use the 10 mm socket wrench to loosen both screws 1 Hold the cover firmly with one hand Completely remove both screws 1 including the washers Pull the cover off towards the side Disconnect the plug in connections if there are tail lights installed in the lateral cover see illustration below 3 SERVICE MANUAL Invacare FDX Series Installing the lateral cover e Connect the plug in connections if there are tail lights installed in the lateral cover Make sure that the markings 1 red tail light and 2 yellow flasher on the power supply cable and on the tail light plug in connection are aligned with each other 38 Invacare FDX Series SERVICE MANUAL e Push the cover from the side between the seat and the chassis e Position both screws 1 including the washers and tighten the screws hand tight 39 40 SERVICE MANUAL Invacare FDX Series 8 1 4 Opening the cover of the rear wheel cantilever arm VA Requirements EU e 4mm Allen key 1 i a Removing the rear cover Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 Pull the cover up in the rear and remove it The cover is held in place by additional Velcro fasteners Installing the rear cover e Assembl
31. 60 8 6 4 Replacing headlamps completely conventional lighting system starting 03 2012 62 8 6 5 Replacing the head lamps completely LED lighting system until 03 2012 64 8 6 6 Replacing headlamps completely LED lighting system starting 03 2012 66 8 6 7 Replacing the head lamp bracket conventional lighting system until 03 2012 68 8 6 8 Replacing headlamp brackets conventional lighting system starting 03 2012 69 8 6 9 Replacing the front bulb holder LED lighting system until 03 2012 70 8 6 10 Replacing a light bulb in the rear conventional lighting system 71 8 6 11 Replacing the LEDs in the rear LED lighting system 71 8 6 12 Replacing the complete tail lamp assembly conventional lighting system until 08 2014 72 8 6 13 Replacing the complete tail lamp assembly conventional lighting system starting 08 2014 74 8 6 14 Replacing the tail lamp bracket conventional lighting system until 08 201 4 76 8 6 15 Replacing the tail lamp bracket conventional lighting system starting 08 201 4 17 8 6 16 Replacing the tail lamps completely LED lighting system 78 8 7 Rear wheels 79 8 7 1 Replacing a rear wheel 79 8 7 2 Replacing a rear wheel fork 80 8 7 3 Adjusting the wheel fork 82 8 8 Drive wheels 84 SERVICE MANUAL Invacare FDX Series 8 8 1 Replacing a drive wheel 84 8 8 2 Replacing a tyre 85 8 8 3 Replacing a drive wheel hub 86 8 9 Replacing the spring in the rear 88 8 10 Replacing the anti tipper wheels 90 8 11 Drive unit 91 8 11 1
32. 6mm Allen key at the same time e Lift the seat off 151 SERVICE MANUAL Invacare FDX Series Uninstalling the seat support adjustable seat simple seat UA Requirements EA e 6mm Allen key e 13mm ring spanner or jaw spanner The following figure shows the seat support with the adjustable seat plate GF aeceseocsa ui a 0 0 a E H i ka e Loosen the Allen key screws 2 with a 6 mm Allen key e Pull the seat frame 1 up and off Installing the seat and seat support e Assemble all parts in reverse order e When installing the seat pay attention to its heavy weight e Tighten the screws to a torque of 25 Nm e Check all functions of the vehicle and go for a test drive 152 Invacare FDX Series 8 17 2 Replacing the tilt actuator O VW Note Replacing the actuator for the seat angle adjustment in the lifter seat tilt adjustment module is also described Requirements Screwdriver flat width 6 mm 13 mm jaw spanner 2x Slotted screwdriver Remove legresis Switch the electronics OFF on the remote Disconnect the actuator cable from the cable harness Variant actuator tilt Bottom fixing bolt 3 with nut 4 Loose the nut with the open ended wrenches Remove the nut and bolt Top fixing bolt 2 secured with snap rings 1 Remove a snap ring using a screwdriver and remove the bolt Pull the actuator out Insert a new actuator Reassembly ta
33. CE MANUAL Invacare FDX Series 8 18 2 Replacing the backrest mounting bracket VA Requirements re e 5mm Allen key Dismantling the backrest unit e Remove the backrest cushion e Loosen the fixation levers 2 of the corresponding backrest tube 1 depending on the version There are two versions 2 for the manual backrest 3 for the electrically adjustable backrest e Remove the backrest tube e Loosen and remove the two hexagon socket head screws 4 to the sliding block 5 on the left and right side of the chair Refitting the backrest unit e Replace the parts in the reverse order e To conclude you should always carry out a trial run to test the vehicle functions 160 Invacare FDX Series SERVICE MANUAL 8 18 3 Replacing the backrest mounting bracket for SB 53 VW Requirements e 5mm Allen key Dismantling the backrest unit e Remove the backrest cushion e Loosen the fixation levers 2 of the corresponding backrest tube 1 depending on the version There are two versions 2 for the manual backrest 3 for the electrically adjustable backrest e Remove the backrest tube A e Loosen and remove the two hexagon socket head screws 4 to the sliding block 5 on the left and right side of the chair Refitting the backrest unit e Replace the parts in the reverse order e To conclude you should always carry out a trial run to test the vehicle functions 161 SERVI
34. CE MANUAL Invacare FDX Series 8 18 4 Adjusting the seat width backrest width 8 18 4 1 Adjusting the seat width Wd 162 You can only adjust the seat width for the adjustable seat plate or for the adjustable sling seat The sling seat is available in two widths for a seat width of 38 43 cm and for a seat width of 48 53 cm When modifying the seat width the backrest width must also be correspondingly adapted See chapter 8 18 4 3 Requirements 3 mm Allen key 5 mm Allen key 13 mm open ended spanner T25 Torx wrench T40 Torx wrench Remove the backrest cushion i C Remove the backrest from the backrest mounting bracket See chapter 8 18 Loosen and remove the screws which secure the middle seat plate A with a 3 mm Allen key Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral seat plates C with a 3 mm Allen key Remove the lateral seat plates D or Remove the seat cushion Loosen and remove the screws on both sides which secure the sling seat A with a T25 Torx wrench Remove the sling seat B N LA Invacare FDX Series e Loosen and remove the screws of the seat frame adjustment A with a T40 Torx e Loosen and remove the screws of the fixation of the legrest mounting brackets wrench B SERVICE MANUAL e Adjust the seat frame and the legrest fixation to the desired width according to the following illustra
35. Invacare FDX Series SERVICE MANUAL CE Edition 1541504 Vers 008 22 10 2014 SERVICE MANUAL Invacare FDX Series These instructions contain information about Testing work Repair Instructions This manual is part of the instructions for use Service addresses CA Invacare Austria GmbH 43 6232 5 53 50 Herzog Odilostrasse 101 Fax 43 6232 5 53 54 A 5310 Mondsee info invacare austria com Austria WWW www invacare at CB Invacare n v o 32 0 50 83 10 10 B Autobaan 22 Fax 32 0 50 83 10 11 CL B 8210 Loppem Brugge belgium invacare com Belgium WWW www invacare be CH Invacare AG 3 41 0 61487 70 80 Rees BenkenstraBe 260 Fax 41 0 61487 70 81 CH 4108 Witterswil switzerland invacare com Switzerland WWW www invacare ch CD Invacare Aquatec GmbH 49 0 7562 70 00 AlemannenstraBe 10 Fax 49 0 7562 7 00 66 88316 Isny info invacare aquatec com Deutschland WWW www invacare aquatec de DK Invacare A S Kundeservice 45 0 36 90 00 00 DK Sdr Ringvej 37 Fax Kundeservice 45 0 36 90 00 01 DK 2605 Br ndby denmark invacare com Danmark WWW www invacare dk CE Invacare SA 34 0 972 49 32 00 c Areny s n Fax 34 0 972 49 32 20 Pol gon Industrial de Celr contactsp invacare com E 17460 Celra Girona WWW www invacare es ESPANA CF Invacare Poirier SAS 33 0 247 62 64 66 i Route de St Roch Fax 33 0 247 42 12 24 F 37230
36. The batteries are very heavy There is a danger that you may injure your hands e Take into account the heavy weight of the batteries e Handle the batteries carefully WARNING Risk of chemical burns Danger of injury by leaking acid e Wear acid resistant protective gloves when handling batteries e Wear protective goggles when handling batteries How to deal with a battery acid leak e Remove clothes that have been soiled or soaked with acid immediately e mmediately wash the affected area of skin that has come into contact with battery acid with lots of water After contact with eyes e mmediately rinse eyes under running water for several minutes Consult an eye doctor immediately afterwards Requirements e 11mm socket wrench e Side cutting pliers e Cable ties 53 SERVICE MANUAL Invacare FDX Series 54 Uninstalling batteries battery cables e Remove the batteries as described in chapter 8 4 1 Positive terminal e Remove the cable ties 1 with side cutting pliers e Lift the battery terminal cap 2 off and move it up the cable and out of the way e Use an 11mm socket wrench to loosen the battery terminal screw 3 e Remove the battery terminal screw together with both washers and the cable lug 5 from the battery terminal 4 Negative terminal e Repeat the steps of the procedure for the positive terminal on the negative terminal of the battery e Replace the batteries and or the ba
37. VICE MANUAL Seat Holes used in seat frame Holes used in seat frame depth in front rear Order no 1524550 Order no 1524555 cm E i RPL Required seat support plate LONG 123 SERVICE MANUAL Invacare FDX Series 124 Adjust the seat depth as described in the following chapters According to subchapter Adjusting the seat depth without replacing the seat support plates if the seat support plates do not have to be replaced According to subchapter Adjusting the seat depth and replacing the seat support plates if the seat support plates have to be replaced Adjusting the seat depth without replacing the seat support plates Remove the armrests Remove the seat cushion Remove the cover plates 1 Loosen and remove the two Allen screws 8 on the rear side of the seat support plate connecting this to the cross braces 4 Repeat this work step on the other side of the seat Loosen and remove the two Allen screws 5 incl the washers Assembly Pull the seat support to the desired length so that the Allen screws 5 can be placed in the holes according to the table see above Refit the Allen screws 5 incl the washers and tighten them Fit the two Allen screws 8 on the rear side of the seat support connecting this to the cross braces 4 Unlike dismantling different holes in the three pairs of holes must be used for the SCrews Refit all parts that were removed Adjusting the seat depth a
38. VICE MANUAL Invacare FDX Series Method 2 uninstalling the lifter actuator with the lifter lowered A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques Ni Requirements e Spring ring pliers Side cutting pliers Cable ties Bent nose pliers 6 mm Allen key ae i 3 Note D Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cables and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so that you can remove the seat 116 Invacare FDX Series SERVICE MANUAL e Loosen and remove the hexagon socket head screw 1 of the seat frame on the left and on the right side of the wheelchair WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques e Lean the seat back and push the rear brackets 2 out of their guides e Remove the seat
39. ackrest frame for the EasyAdapt backrest 137 8 16 Back unit with ergonomic length adjustment 140 8 16 1 Adjusting the width 140 8 16 2 Replacing the planetary gear 141 8 16 3 Replacing the servo motor 143 8 16 4 Replacing the microswitch 144 8 16 5 Fitting back plates to the base support of the back with ergonomic length adjustment 145 8 16 6 Fitting the handlebar 146 8 16 7 Replacing the travelling armrest 147 8 16 8 Replacing the arm support on the travelling armrest 148 8 16 9 Retrofitting a travelling armrest 149 8 17 Seat adjustment Modulite 150 Invacare FDX Series 8 18 4 seat seat frame Modulite without lifter Replacing the tilt actuator Replacing the lifter actuator Replacing the lifter seat angle adjustment module Replacing the backrest actuator Backrest Modulite Replacing the standard backrest Replacing the backrest mounting bracket Replacing the backrest mounting bracket for SB 53 Adjusting the seat width backrest width 8 18 4 1 Adjusting the seat width 8 18 4 2 Adjusting the seat width legrest LNX 8 18 4 3 Adjusting the backrest width 8 18 4 4 Adjusting the Flex3 backrest 8 19 8 19 1 8 19 2 Fixation rings Replacing a front fixation ring Replacing a rear fixation ring 9 INSTALLING ACCESSORIES 9 1 Replacing the restraining belt Replacing the harness belt Replacing seat belts Modulite seat Installation on the backrest mounting bracket simple backrest Installation on the backrest mount
40. adjusted during installation 93 94 SERVICE MANUAL 8 11 3 A Li Invacare FDX Series Replacing the motor gearbox coupling CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight Requirements e 10mm socket wrench Uninstalling the motor gearbox coupling e Uninstall the motor gearbox unit as described in chapter 8 11 1 e Use the 10 mm socket wrench to loosen and remove the self securing nut 4 e Remove the carriage bolt which secures the sealing ring 2 e Carefully bend the sealing ring apart and remove tt WARNING Danger of damage to the wheelchair if the coupling is not serviced correctly e Becareful not to damage the coupling mechanism during maintenance work e Carefully pull the motor 3 and the gearbox 1 apart e Remove the component parts of the coupling e f necessary replace the coupling Invacare FDX Series SERVICE MANUAL Installing the motor gearbox coupling e Place the new clutch 7 on the motor axle Pay attention to the position of the groove e Position the locking ring 5 on the motor 4 or the gearbox 1 e Carefully insert the motor into the gearbox Pay attention to the position of the groove in the axle of the gearbox If necessary rotate the motor and gearbox in the same position as before assembly e Insert the carriage bolt through the locking ring Do no
41. al lighting system until 03 2012 Ni Requirements ad e Phillips screwdriver size 2 e Side cutting pliers e Cable ties Uninstalling head lamps e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected head lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair 60 Invacare FDX Series SERVICE MANUAL Loosen both of the cap nuts 1 with an 8 mm open end wrench and remove the head lamp with the bracket from the rubber mounting Not shown in the illustration are two Phillips head screws with which the head lamp is secured to the bracket Loosen both of these Phillips head screws to remove the head lamp from the bracket Replace the head lamp Installing head lamps Assemble all parts again in reverse order Install the cables carefully and secure them with cable ties Make sure that the cables not are not pinched or stretched Tighten both screws hand tight Check all vehicle functions Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 61 SERVICE MANUAL Invacare FDX Series 8 6 4 Replacing headlamps comple
42. bracket e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions e Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 68 Invacare FDX Series SERVICE MANUAL 8 6 8 Replacing headlamp brackets conventional lighting system starting 03 2012 Ni Requirements ad e Phillips screwdriver size 2 e Open end wrench 8 mm Uninstalling the tail light bracket e Loosen both of the nuts 1 with an 8 mm open end wrench and remove the headlight with the bracket from the rubber mounting e Loosen both Phillips head screws 2 to remove the headlight from the bracket e Replace the bracket Installing the headlight bracket e Assemble all parts again in reverse order e Tighten the screws hand tight e Check all vehicle functions e Perform an approximate adjustment of the headlight using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 69 SERVICE MANUAL Invacare FDX Series 8 6 9 Replacing the front bulb holder LED lighting system until 03 2012 VW 70 Requirements e 4mm Allen key e 8mm spanner Dismantling the bulbholder Loosen the Allen screw 1 using a 4 mm Allen key and remove the headlight from the mounting Loosen the t
43. c sensor Installing the G Trac sensor e Assemble the parts in reverse order e Reconnect all cable connectors to their former positions e The G Trac sensor must be installed with the cable pointing upwards e The last step is to test all functions of the vehicle 45 SERVICE MANUAL Invacare FDX Series 8 2 4 O 8 2 4 1 46 Drive program selection after component replacement The drive program is saved in the REM remote and also in the DX ACS or ACS2 electronic module If one of these two components is replaced the system must be told which of the components has not been replaced so that it knows which contains the current controller profile Note The system allows normal usage of the mobility aid after component replacement only if the profile is selected afterwards Profile selection with G90A remote e Connect the plug to the remote or the ACS2 electronic system respectively e The display 1 will indicate that you should select a profile e Use the arrow keys 2 to select the location where the desired controller profile is stored Remote Il Electronic module e The display will indicate which profile you have selected e Press the Horn key 3 and the Drive Mode key 2 and keep them pressed for 3 seconds to confirm the selection e The system switches itself off and starts again automatically During this process the selected profile is stored in the remote as well as in the electronic m
44. cid resistant protective gloves when handling batteries e Wear protective goggles when handling batteries How to deal with a battery acid leak e Remove clothes that have been soiled or soaked with acid immediately e mmediately wash the affected area of skin that has come into contact with battery acid with lots of water After contact with eyes e mmediately rinse eyes under running water for several minutes Consult an eye doctor immediately afterwards Requirements e Phillips screwdriver size 2 e Side cutting pliers e Cable ties Uninstalling the batteries e Remove the legrests e Remove the front cover as described in chapter 8 1 1 Invacare FDX Series SERVICE MANUAL e Disconnect the plug in connection 1 of the front battery 2 e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e f necessary remove the cable ties that secure the bundles of cables to the chassis on both sides of the electronic modules e Position the bundles of cables so that they lie outside of the fixation screws 1 of the electronic module brackets e Loosen and remove both fixation screws of the electronic module brackets including the washers with a Phillips screwdriver 51 SERVICE MANUAL Invacare FDX Series 52 e Disconnect the plug i
45. connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected headlight from the lighting circuit board e Open the cable clamps 1 remove all cable ties and pull the cable out of the wheelchair 66 Invacare FDX Series SERVICE MANUAL Loosen the hexagon socket head screw 1 with a 4 mm Allen wrench and remove the headlight from the bracket Replace the headlight Installing headlights Assemble all parts again in reverse order Install the cables carefully and secure them with the cable clamps and cable ties Tighten the screws hand tight Check all vehicle functions Perform an approximate adjustment of the headlight using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 67 SERVICE MANUAL Invacare FDX Series 8 6 7 Replacing the head lamp bracket conventional lighting system until 03 2012 Ni Requirements EU e Phillips screwdriver size 2 e 8 mm socket wrench Uninstalling the head lamp bracket e Loosen both of the cap nuts 1 with an 8 mm socket wrench and remove the head lamp with the bracket from the rubber mounting e Not shown in the illustration are two Phillips head screws with which the head lamp is secured to the bracket Loosen both of these Phillips head screws to remove the head lamp from the bracket e Replace the bracket Installing the head lamp
46. ction plug See chapters 8 4 5 hand motor M2 check motor and 7 1 Connection loose defective or motor defective Fault orake fault on right Check connection plug see chapters 8 4 5 hand motor M19 check motor and 7 1 Connection loose defective or motor defective 7 x blink Completely discharge Pre charge battery See operating manual battery Battery voltage too high Switch lighting to low See charging unit battery voltage operating manual Check battery charger 9 or 10 x blink Faulty data transmission Remove electronic modules See chapter 8 2 2 between modules except for the power module and the remote Replace the modules one after another in order to ensure which was the one causing the fault 29 SERVICE MANUAL Invacare FDX Series BLINK CODE POSSIBLE CAUSE SOLUTION DOCUMENTATION Drive motors overloaded Switch remote on and off overheated wait if necessary Compatibility problems Remove incorrect module See chapter 8 2 2 between modules 30 Invacare FDX Series SERVICE MANUAL 6 3 Diagnosis of charging device faults SYMPTOM No LEDs illuminating on battery charger Batteries do not charge POSSIBLECAUSE CAUSE SOLUTION Charging device not Ensure that the battery connected to mains supply charger has been plugged in No mains supply Check the mains supply with a voltmeter Defective mains supply cable Check the mains supply cable Replace damaged cables
47. d feet e Use proper lifting techniques Requirements 6 mm Allen key Torque wrench 5 30 Nm or similar Protractor Side cutting pliers Cable ties Wooden block Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Removing the seat e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Detach all cables from the electronic modules which run from the seat to the chassis e Place the cables so that they do not get in the way when you remove the seat Invacare FDX Series SERVICE MANUAL e Insert a suitable wooden block 2 between the seat 1 and the chassis 3 This will prevent the seat from falling down when you loosen and remove the screws WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques e Use the 6 mm Allen key to loosen and remove the screws 4 on both sides in the front at the same time e Hold the seat securely and loosen the rear hexagon socket head screw 5 on both sides with a
48. de of the module This way it is possible to reach the lower fixation bolt of the actuator Invacare FDX Series 8 17 4 Replacing the lifter seat angle adjustment module O A Vid Note Replacement of the seat angle adjustment module is performed in the same manner ATTENTION Danger of crushing The seat seat frame is very heavy Danger of injury to hands and feet Use proper lifting techniques Requirements 3 mm Allen key 5 mm Allen key T25 Torx wrench T40 Torx wrench Side cutting pliers Cable ties Remove legrests Tilt the seat tilting completely to the rear if possible Switch the electronics OFF on the remote Remove the backrest cushion Loosen and remove the screws which secure the middle seat plate A with a 3 mm Allen key Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral seat plates C with a 3 mm Allen key Remove the lateral seat plates D or Remove the seat cushion Loosen and remove the screws on both sides which secure the sling seat A with a T25 Torx wrench Remove the sling seat B SERVICE MANUAL 155 SERVICE MANUAL Invacare FDX Series e Remove the seat frame by removing the screws 1 with a T40 Torx wrench e Disconnect the actuator cable and microswitch cable from the cable harness 156 Invacare FDX Series SERVICE MANUAL i aoe e Loosen and remove the screws 2
49. dling of your product and refers to special functions SERVICE MANUAL Invacare FDX Series 1 4 amp PP P PP Pb a Ss X Hazard symbols and symbols used Different types of hazard symbols and symbols are used throughout this manual General hazards This symbol warns you of general hazards e Always follow the instructions to avoid injury to the user or damage to the product BURN HAZARD This symbol warns you of the danger of chemical burns for example due to the discharge of battery acids e Always follow the instructions to avoid injury to the user or damage to the product DANGER OF CRUSHING This symbol warns you of crushing hazards due to inattentive working with heavy components e Always follow the instructions to avoid injury to the user or damage to the product EXPLOSION HAZARD This symbol warns you of an explosion hazard which can be caused by excessive tyre pressure in a pneumatic tyre e Always follow the instructions to avoid injury to the user or damage to the product Wear safety shoes The symbol refers to the requirement for wearing safety shoes e Wear standardised safety shoes during all work Wear eye protection This symbol refers to the requirement for wearing eye protection for example when working with batteries e Wear eye protection when this symbol is shown Wear safety gloves This symbol refers to the requirement for wearing safety gloves for example when
50. e centre of gravity of the wheelchair e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame Invacare FDX Series SERVICE MANUAL e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so it can be removed from the lifter module later along with the actuator A WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Use proper lifting techniques e Carefully secure the seat against closing or falling down unintentionally before removing the actuator If there is no means to secure the seat from falling down remove it entirely e Inacombined lifter tilt module the lifter actuator is located in the lower part of the module p e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolts 4 out of the guides Pay attention to the bushings 3 on the front bolt e Remove the actuator from the lifter module Installing the lifter actuator e Assemble all parts in reverse order e Perform a function test 115 SER
51. e electronic module is to be replaced Remove the electronic module Replace the defective modules Installing electronic modules Install the various modules in reverse order Reconnect all cable connectors to their former positions If you have replaced ACS2 electronic module please select the correct drive program as described in chapter 8 2 4 Update the drive program in case a new software version is available as described in chapter 8 3 Modify the drive program using the programming software as needed The last step is to test all functions of the vehicle 43 SERVICE MANUAL Invacare FDX Series 8 2 3 Replacing the G Trac sensor VA Requirements EAF e 10 mm socket wrench e Side cutting pliers e Cable ties Uninstalling the G Trac sensor e Switch the electronic of the wheelchair OFF e Remove the front rear and right lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 The G Trac sensor is located on the spring seat of the right hand spring e Trace the cable of the G Trac sensor 1 to the electronic module and disconnect it there e Pull the cable out of the wheelchair If necessary remove any attached cable ties 44 Invacare FDX Series SERVICE MANUAL e Use the 10 mm socket wrench to loosen and remove the self securing nuts 3 including the washers e Pull the G Trac sensor 2 off of the carriage bolt 1 which is inserted in the spring seat e Replace the G Tra
52. e of between 15 ohms and infinity indicates a defective motor High resistances are normally caused by bad connections or worn carbon brushes 32 Invacare FDX Series SERVICE MANUAL 7 2 Testing the electro mechanical parking brake Note GD This test should only be carried out on mobility aids with conventional motor transmission units YA Requirements EA e Phillips screwdriver size 2 e digital multimeter with resistance measurement e Remove the rear panel as described in Chapter 8 1 2 ee SA a mi i a Kay mN P j k Si oc AA ADA N y i NG 2 w oa ken EA P i iu Hin feo of e Connect the digital multimeter to the adjacent central motor plug contacts 3 and measure the resistance between the contacts e lf there is a defect replace the motor and send it to Invacare Service for inspection or repair Note Q A resistance of between 40 and 80 ohms indicates an intact brake A resistance of 0 ohms or a very high resistance mega ohms or infinity indicates a short circuit a bad connection or a defective brake 33 SERVICE MANUAL Invacare FDX Series amp 34 CAUTION Material damage can be caused to the electronic module due to short circuit in the electro mechanical brake e NEVER connect an electro mechanical brake to an intact electronic module with a short circuit e Always replace short circuited brakes immediately Note A defective motor can damage the electronic mod
53. e opposite nut on the right side of the mobility aid Remove the Allen screws 2 incl the washers and the nut if necessary Pull the planetary gear from the axle Replace the planetary gear 141 SERVICE MANUAL Invacare FDX Series Refitting the planetary gear e Refit the parts in reverse order e To conclude check all the mobility aid functions 142 Invacare FDX Series SERVICE MANUAL 8 16 3 Replacing the servo motor W Requirements 4 mm Allen key 5 mm Allen key 10 mm socket spanner 13 mm jaw spanner Size 2 Phillips recessed head spanner Snap ring pliers Fitting the planetary gear e Disconnect the two motor plugs 1 e Dismantle the entire back section and remove both planetary gears as described in chapter 8 16 2 e Loosen and remove the two nuts 2 only the upper nut is visible in the illustration e The motor 5 and the gear 4 form one unit Pull them from the axle together 3 e Replace the motor gear unit Refitting the planetary gear e Refit the parts in reverse order e To conclude check all the mobility aid functions 143 SERVICE MANUAL Invacare FDX Series 8 16 4 Replacing the microswitch VV Requirements EU e 4mm Allen key e Size 2 Phillips recessed head spanner Dismantling the microswitch e Loosen and remove the four Allen screws on the backrest plastic cover using a 4 mm Allen key e Remove the plastic cover e Pull the plugs 2 out of the
54. e parts in reverse order 89 SERVICE MANUAL Invacare FDX Series 8 10 Replacing the anti tipper wheels VA Requirements a e Small flat screwdriver e Two 13mm socket wrenches Uninstalling an anti tipper wheel Carefully remove the black plastic cap 3 from the middle of the anti tipper wheel 2 with a small flat screwdriver Loosen the self securing axle nut which is located underneath the plastic cap not visible in the illustration using a 13 mm socket wrench Secure the axle 4 against slippage using a second 13 mm socket wrench Remove the axle nut and the washer Pull the wheel 2 off of the axle Replace the wheel and or the ball bearing The ball bearings are inserted in the wheel They can be removed using a small screwdriver Installing an anti tipper wheel 90 Assemble the parts in reverse order When installing the ball bearings make sure you do not forget to insert the distance sleeve between the ball bearings When repositioning the wheel on the axle make sure you do not forget the spacer washer 5 Tighten the self securing axle nuts just tight enough that the wheel can still rotate without resistance When rotated very quickly it must not start to wobble Invacare FDX Series SERVICE MANUAL 8 11 Drive unit 8 11 1 Replacing the motor gearbox unit A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting technique
55. e the parts in reverse order Invacare FDX Series SERVICE MANUAL 8 2 8 2 1 Electronic modules Replacing remotes Note The procedure to replace remotes is trivial and is not described in detail However when replacing a REM remote in connection with a DX ACS or ACS2 electronic module please make sure to select the correct drive programme as described in chapter 8 2 4 Replacing electronic modules Note When replacing a REM remote in connection with a DX ACS or ACS2 electronic module please make sure to select the correct drive programme as described in chapter 8 2 4 Various different types of electronic modules can be installed in connection with different remotes in the wheelchair The electronic modules that might be installed are described in chapter 4 2 The procedure to replace components is described using the ACS2 electronic module with an optional lighting circuit board and optional actuator module as an example The procedure is identical for other electronic modules The only difference is the position of the plug in connections WARNING Every alteration to the drive programme can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive programme must only be carried out by authorised Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for this standard unaltered drive
56. egrests e Remove the front cover as described in chapter 8 1 1 e Remove the batteries as described in chapter 8 4 1 e Jack up the mobility aid using several wooden blocks Use proper lifting techniques e Fit the reinforcement plates 7 8 by attaching the reinforcement plate 8 with the screws 5 and 6 to the chassis see picture on page 181 e Calculate the required screw and choose the correct screws 4 e Fit the spacers 2 the safety plate 3 and the special nuts 9 e Fit the Allen screws 4 with a high strength screw blocker system such as Loctite 270 e Fit the batteries as described in chapter 8 4 1 Note Fit new retaining plates 10 including screws and washers e Fit the remaining parts in the reverse order e To conclude check all fittings for secure connection Removing the DAHL Docking Station e Disassemble the parts in reverse order than described in chapter Fitting the DAHL Docking Station 183 SERVICE MANUAL Invacare FDX Series 9 5 Fitting the stick holder YA Requirements IZ e 5 mm Allen key e Phillips screwdriver size 2 e Insert the Phillips screw 2 through the borehole of the loop 3 e Attach the Phillips screw and the loop to the borehole 1 of the handlebar and tighten the Phillips screw with a Phillips screwdriver e Loosen and remove the two Allen screws 6 incl the washers on the lower part of the backrest hinge 4 e Hold the lower mounting 5 with
57. er wheels as described in chapter 8 10 e f necessary install the conventional rear lighting system as described in chapters 8 6 10 and 8 6 14 e Install the batteries as described in chapter 8 4 1 e Install the seat including the seat frame as described in chapter 8 13 and 8 17 e Install all electronic modules that are fitted in the rear on the battery box as described in chapter 8 2 2 e Install all plastic covers as described in chapter 8 1 e Install the drive wheels as described in chapter 8 8 1 e Perform a comprehensive driving and function test with the wheelchair 58 Invacare FDX Series SERVICE MANUAL 8 6 O 8 6 1 Wg 8 6 2 Lighting system Note There are two different lighting units A conventional lighting unit with bulbs and a LED lighting unit Replacing light bulbs in the front conventional lighting system Requirements e Phillips screwdriver size 2 e Loosen the concealed Phillips head screw on the back of the head lamp turn indicator combination e Remove the transparent plastic cover e Replace the defective light bulb e Reposition the cap and tighten the Phillips head screw hand tight Replacing the LEDs in the front LED lighting system e Individual LEDs are not intended to be replaced Replace the complete lighting system as described in chapter 8 6 5 59 SERVICE MANUAL Invacare FDX Series 8 6 3 Replacing the complete head lamp assembly convention
58. erse order Make sure that seat tilt mounting brackets 2 are affixed with screws to the top holes in the seat frame brackets 5 Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting brackets to 18 Nm When installing the cables again make sure that they are placed in such a way that they cannot be crushed or damaged in any position of the tilt module WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques Install the seat Install all covers again Check all functions of the vehicle and go for a test drive 107 SERVICE MANUAL Invacare FDX Series 8 13 2 2 Replacing the lifter tilt module i 108 Note This chapter describes how to replace the seat frame on a wheelchair with a lifter tilt module Similar tasks are described In the following chapters e Replacing the seat frame alone chapter 8 13 1 e Replacing a tilt module chapter 8 13 2 1 e Replacing just the tilt actuator chapter 8 13 2 3 e Replacing just the lifter actuator chapter 8 13 2 4 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques Requirements 13 mm open ended wrench 4 mm Allen key 6 mm Allen key 6 mm wrench Side cutting pliers Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in t
59. ghting circuit board 18 4 3 Remotes 19 5 MAINTENANCE PLAN ONCE A YEAR 21 6 OPERATIONAL FAULTS 24 6 1 Drive fault diagnosis 25 6 2 REM remotes Error codes and diagnostic codes 29 6 3 Diagnosis of charging device faults 31 Invacare FDX Series SERVICE MANUAL 7 TEST PROCEDURES 32 7 1 Testing the motor 32 7 2 Testing the electro mechanical parking brake 33 8 REPAIR WORK 35 8 1 Covers 35 8 1 1 Open front cover 35 8 1 2 Opening the rear cover 36 8 1 3 Opening the lateral cover 37 8 1 4 Opening the cover of the rear wheel cantilever arm 40 8 2 Electronic modules 41 8 2 1 Replacing remotes 41 8 2 2 Replacing electronic modules 41 8 2 3 Replacing the G Trac sensor 44 8 2 4 Drive program selection after component replacement 46 8 2 4 1 Profile selection with G90A remote 46 8 2 4 2 Profile selection with remote REM A or REM B 47 8 2 4 3 Profile selection with remote REM 550 48 8 3 Updating the driving program 49 8 4 Batteries cables amp battery chargers 50 8 4 1 Removing the batteries 50 8 4 2 Replacing batteries replacing battery cables 53 8 4 3 How to handle damaged batteries correctly 55 8 4 4 Replacing the main fuse 55 8 4 5 Checking the cables 56 8 5 Replacing the battery boxes 58 8 6 Lighting system 59 8 6 1 Replacing light bulbs in the front conventional lighting system 59 8 6 2 Replacing the LEDs in the front LED lighting system 59 8 6 3 Replacing the complete head lamp assembly conventional lighting system until 03 2012
60. he angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the lifter tilt module e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame Invacare FDX Series SERVICE MANUAL e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up all cables so that you can lift the seat off WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques e Loosen the four screws 1 that attach the seat to the lifter tilt module using a 4 mm Allen key and a 13 mm open end wrench e Lift the seat up off of the lifter module tilt module Use proper lifting techniques 109 SERVICE MANUAL Invacare FDX Series 110 Open the power supply chain of the lifter Flip the cover 1 up Pull the flap 2 out of the cover Repeat this procedure link by link Remove both cable ties that secure the cable at the ends of the power supply chain Pull the cab
61. hich are not listed here fingertight Invacare FDX Series SERVICE MANUAL 4 Arrangement of sub assemblies and components 4 1 Overview In the rear under the seat Electronic modules The electronic modules are located under the rear cover 1 Electronic module 2 Actuator module optional 3 Lighting circuit board optional amp not shown in the illustration The electronic modules that are installed are described in chapter 4 2 In the front under the seat 1 Actuator module optional 2 Lifter actuator optional 3 Tilt actuator optional On the right next to the spring seat 1 G Trac sensor optional 15 SERVICE MANUAL Invacare FDX Series 4 2 Electronic modules Various different types of electronic modules can be installed in the wheelchair Before you connect components of the wheelchair such as adjustment motors or actuators to the electronic module make sure you know exactly which electronic module is installed The following table provides an overview ACS2 PMB70 ACS2 PMB70L ACS2 PMA90LG ACS2 with actuator module ACT The actuator module is optional Actuator module The actuator module ACT is optional Lighting circuit The lighting circuit board board is optional G Trac sensor The G Trac sensor is optional Invacare FDX Series SERVICE MANUAL 4 2 1 ACS2 PMB70 ACS2 PMB70L electronic module Connections 1 Batte
62. ial quality must be at least 8 8 If spacers have been fitted the screws length should be completed as follows A thickness of safety plate and spacers A 1 mm Screw length B Height of spacers Note When installing the plates ensure the correct screw length A 1 mm is used Longer screws could damage the batteries Fitting the DAHL Docking Station prepared wheelchair e Remove the legrests e Remove the front cover as described in chapter 8 1 1 e Remove the batteries as described in chapter 8 4 1 e Jack up the mobility aid using several wooden blocks Use proper lifting techniques e Loosen and remove the five bolts 1 including the washers on the underside of the chassis e Calculate the required screw length in accordance with the above formula e Select five M8 Allen key countersunk screws 4 in accordance with DIN 7991 material quality at least 8 8 to suit the calculated length e Fit the spacers 2 and the safety plate 3 over the drillholes with the special nuts 9 e Fit the Allen screws 4 with a high strength screw blocker system such as Loctite 270 e Fit the batteries as described in chapter 8 4 1 Note O Fit new retaining plates 10 including screws and washers e Fit the remaining parts in the reverse order e To conclude check all fittings for secure connection 182 Invacare FDX Series SERVICE MANUAL Fitting the DAHL Docking Station unprepared wheelchair e Remove the l
63. ing bracket adjustable seat Installation on the seat frame profile adjustable seat Replacing the harness belt adjustable seat Replacing the harness belt simple seat DAHL Docking Station Fitting the stick holder Further accessories SERVICE MANUAL SERVICE MANUAL Invacare FDX Series 1 1 1 2 Introduction General information service and maintenance work must be carried out taking this service manual into account lt is imperative that you observe safety information Information about operation or about general maintenance and care work on the mobility aid should be taken from the operating manual You can find information about ordering spare parts in the spare parts catalogue Only use original Invacare spare parts The guarantee will become invalid if other spare parts are used We reserve the right to make any alterations on the grounds of technical improvements The mobility aid may only be maintained and overhauled by qualified personnel The minimum requirement for service technicians is suitable training such as in the cycle or orthopaedic mechanics fields or sufficiently long term job experience Experience in the use of electrical measuring equipment multimeters is also a requirement Special Invacare training is recommended Alterations to the mobility aid which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the
64. kes place in the reverse order Connect the actuator cable to the cable harness To complete check all seat tilting function Variant seat angle adjustment actuator in the lifter seat angle adjustment module Bottom fixing bolt 3 with slot Loosen the fixing bolt with a screwdriver Remove the bolt Top fixing bolt 2 secured with snap rings 1 Remove a snap ring using a screwdriver and remove the bolt Pull the actuator out Insert a new actuator Reassembly takes place in the reverse order Connect the actuator cable to the cable harness To complete check all seat tilting function SERVICE MANUAL 153 SERVICE MANUAL 8 17 3 Replacing the lifter actuator W 154 Requirements Screwdriver flat width 6 mm Large screwdriver Flat screwdriver Remove legrests Run the lifter up to if possible Switch the electronics OFF on the remote Secure the seat Pull the plug from the actuator Bottom fixing bolt 2 secured with snap rings Remove a snap ring using a screwdriver and remove the bolt Top fixing bolt 3 with slot Loosen the fixing bolt with a screwdriver Remove the bolt Replace actuator Reassembly of the actuator takes place in the reverse order Connect the plug of the actuator cable to the actuator To complete check all seat tilting function Invacare FDX Series lf the lifter cannot be raised a cover can be removed from the upper rear si
65. le out of the power supply chain Use the Phillips screwdriver to loosen the screws 1 Remove the power supply chain 2 Use the Phillips screwdriver to loosen the screws 4 Additionally the sensor 5 is secured with nuts Loosen the nuts by holding against a 6 mm wrench Remove the magnet 3 Remove the sensor 5 Invacare FDX Series SERVICE MANUAL kL al ral k j a ae as a ry b E ae eg h F a at kA i Par F T a Fir F F Ff a P a d wo y T Er Fi te ol j j a hat r i eS oe z oll hat a iy o Whe a a ie Y B h as Fa a 5 ao 4 i Fs a mi a i s igy Q o Pan I Gi fi S o a 2 i e q 4 k Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws 3 on both sides of the wheelchair Remove the screws and the washers Lift the tilt module 1 up off of its brackets 2 If one of the seat tilt mounting brackets 2 are to be replaced Use the 6 mm Allen key to loosen both screws 4 on the corresponding side of the wheelchair Remove the screws and the washers Remove the tilt mounting bracket If one of the seat frame mounting brackets 5 are to be replaced Disassemble the seat frame mounting brackets as described in chapter 8 13 1 starting from the section header Uninstalling the seat frame Installing the tilt module Install the tilt module in reverse order Make sure that seat tilt mou
66. length adjustment 8 16 1 Adjusting the width i Note GD Please also observe preceding chapter 8 13 3 1 on adjusting the seat width By default the seat can be adjusted in width between 38 and 53 cm WO Sr e Remove the back cushion e Loosen the three Allen screws 1 but do not remove them completely e Move the plate 2 until the desired width in centimetres can be read off the scale 3 e Tighten the three Allen screws e Repeat this work step on the other back plate e Fit aback cushion in the appropriate width 140 Invacare FDX Series SERVICE MANUAL 8 16 2 Replacing the planetary gear Requirements 4 mm Allen key 5 mm Allen key 13 mm jaw spanner Size 2 Phillips recessed head spanner Snap ring pliers Dismantling the planetary gear Loosen and remove the four Allen screws on the plastic cover 1 using a 4 mm Allen key Remove the plastic cover Loosen and remove the Phillips screw 3 Remove the reflector 4 Remove the snap ring under the reflector not in the picture Undo the two Allen screws 6 with a5 mm Allen key Remove the Allen screws 6 incl the washers and the stick holder 5 if necessary When replacing both planetary gears or dismantling the entire back section also now loosen and remove the Allen screws 6 incl the washers on the other side of the mobility aid Undo the two Allen screws 2 with a5 mm Allen key You will need an additional 13 mm jaw spanner for th
67. ling the tilt actuator e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so it can be removed from the tilt module later along with the actuator Invacare FDX Series SERVICE MANUAL A WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Use proper lifting techniques e Carefully secure the seat against falling down unintentionally before removing the actuator If there is no means to secure the seat from falling down remove it entirely e In acombined lifter tilt module the tilt actuator is located in the upper part of the module 2 e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolts 4 out of the guides Pay attention to the bushings 3 on the front bolt e Remove the actuator from the tilt module Installing the tilt actuator e Assemble all parts in reverse order e Perform a function test 113 SERVICE MANUAL Invacare FDX Series
68. microswitch 1 e Loosen and remove the two Phillips screws 3 e Replace the microswitch Refitting the planetary gear e Refit the parts in reverse order e To conclude check all the mobility aid functions 144 Invacare FDX Series SERVICE MANUAL 8 16 5 Fitting back plates to the base support of the back with ergonomic length Md adjustment Requirements e 4mm Allen key Loosen the three Allen screws 1 but do not remove them completely Move the back plate 2 so that the large boreholes 3 are above the lower screw holes of the centre back plate Tighten the three Allen screws slightly Repeat this on the second back plate Move the back of the seat to the rearmost position Slide the two lower slot nuts 4 in the left hand and right hand groove right down to the bottom Push the upper ones so far to the top that the distances of the slot nuts coincide with the distances of the screw holes Place the centre part of the back plate 3 on the backrest so that the four boreholes coincide with the slot nuts 4 Fit the four supplied Allen screws and tighten them Adjust the desired seat width with the help of the included centimetre scale Tighten the six Allen screws 1 firmly 145 SERVICE MANUAL Invacare FDX Series 8 16 6 Fitting the handlebar Ni Requirements EU e 4mm Allen key e Loosen and remove the four Allen screws 3 on the plastic cover e Remove the plastic cove
69. n and rear wheel cantilever arm WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors Secure the vehicle against rolling away by placing wedges under the wheels UA Requirements yg 22 mm socket wrench 5mm Allen key Torque wrench 20 80 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Dismantling the motor gearbox fixation and rear wheel cantilever arm 100 Lift the wheelchair on one side and place a 14 cm high wooden block underneath the battery compartment so that the wheels are off the ground and can rotate freely Use proper lifting techniques Repeat this on the other side of the wheelchair Remove the drive wheel as described in chapter 8 8 1 Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 Remove the drive wheel as described in chapter 8 8 1 Use the 5 mm Allen key to loosen and remove both screws 1 Remove the black plastic stop that is held by the screws Push the rear wheel cantilever arm 4 downwards Remove the spring 3 Invacare FDX Series SERVICE MANUAL e Use the 22 mm socket wrench to loosen and remove the self securing nut 2 e Remove the washer e Pull the motor gearbox fixation and
70. n connection 1 of the rear battery 2 e Disconnect the battery cable from the electronic module e Liftthe electronic module bracket up and remove it Pull the bracket towards the rear and let it hang over the back end of the wheelchair e Pull both batteries backwards out of the chassis and remove them Take into account the heavy weight of the batteries Installing batteries e Install the batteries in reverse order e Make sure the battery box sockets and plugs are correctly installed A schematic showing the correct positions can be found in the battery box cover Invacare FDX Series SERVICE MANUAL 8 4 2 Replacing batteries replacing battery cables A W Note To replace the fuse the battery cable with the fuse attached to it must be replaced CAUTION Danger of injury and danger of damage to property if the batteries are handled incorrectly e The installation of new batteries may only be performed by authorised technicians e Pay attention to the warning notes on the batteries e Only use the battery type defined in the technical specifications CAUTION Risk of fire and burns if battery terminals are short circuited e Take special care that the battery terminals are NOT short circuited with a tool or metallic components of the wheelchair e Make sure that the battery terminal caps are fitted to the battery terminals at all times if you are not working on them CAUTION Danger of crushing
71. n socket head screws 2 to a torque of 25 Nm 85 SERVICE MANUAL Invacare FDX Series 8 8 3 Replacing a drive wheel hub A WARNING Danger of damage to the wheelchair Collisions can be caused if shim rings are removed from the drive wheels during installation work e Shim rings are frequently placed between the drive shaft and the wheel hub to compensate tolerances Collisions can be caused if these shim rings are removed and not re installed e Please install all shim rings in exactly the same positions they were before disassembly Vii Requirements EAF e 19mm socket wrench e Torque wrench 10 80 Nm or similar Uninstalling a drive wheel hub e Use the 19 mm socket wrench to loosen and remove the axle nut 4 e Remove the washer 3 e Pull the wheel hub 5 off of the axle 2 e Remove the feather key 1 from the axle Installing a drive wheel hub 86 Invacare FDX Series SERVICE MANUAL e Assemble the parts of the wheel hub in reverse order e Between the wheel and the motor drive unit distance rings of various widths are inserted to adjust the clearance between the wheel and the motor Select the correct width for the distance rings e Use a thin film of lubricant to replace the wheel hub on the axle e Tighten the screws to a torque of 60 Nm 87 SERVICE MANUAL Invacare FDX Series 8 9 amp Vd f 88 Replacing the spring in the rear Note Invacare rec
72. nd replacing the seat support plates Disassembly Remove the legrests Remove the armrests Remove the seat cushion Remove any existing cable ties holding the remote or lighting cables Release the cables from the stuck on clamps Loosen the cap nuts of the headlight mountings using an 8 mm jaw spanner see chapter 8 6 3 or 8 6 5 Put the headlights and the mounting in a safe place on the rear part of the battery compartment cover Remove the cover plates 1 Loosen the two Allen screws 9 at the top front of the seat support plate and remove them Loosen the two Allen screws 7 on the front side of the seat support plate connecting this to the cross braces 4 Loosen the two Allen screws 8 on the rear side of the seat support plate connecting this to the cross braces 4 Remove the seat support plate 2 Repeat this work step on the other side of the seat Loosen and remove the two Allen screws 5 incl the washers Invacare FDX Series SERVICE MANUAL e Pull the seat support to the desired length so that the Allen screws 5 can be fitted into the holes according to the table see above e Refit the Allen screws 5 incl the washers and tighten them e f necessary replace the seat support plates 2 according to the table see above e Refit the seat support plate 2 e Fit the two Allen screws 7 on the front side of the seat support connecting this to the cross braces 4 e Fit the two Allen
73. ns 26 Invacare FDX Series SERVICE MANUAL PROBLEM OTHER SOLUTION DOCUMENTATION SYMPTOMS POSSIBLE CAUSE Cabling to check cabling See chapter 8 4 5 electronic module or joystick defective Electronic Replacing the see chapter 8 2 2 module electronic module defective Corroded Water salt or Check cabling see chapter 8 4 5 contacts urine has replace if penetrated necessary Motor makes None Clutch es Replace clutch See chapter 8 11 3 clicking noise defective Bearing Replacing the see chapter 8 11 1 defective motor Collector Measure internal see chapters 7 1 defective resistance of and 8 11 1 motor replace motor if defective Scraping noise None Clutch es Replace clutch See chapter 8 11 3 or motor defective PIOEKE Bearing Replacing the see chapters 8 11 1 defective motor and 8 11 3 Transmission Replace see chapters 8 11 1 defective transmission and 8 11 3 Transmission None Transmission Replace see chapters 8 11 1 makes clicking defective transmission and 8 11 3 noise Drive wheel Tighten drive see chapter 8 8 1 loose wheel secure bolts with Loctite if necessary Transmission None sealing ring on Replace see chapters 8 11 1 losing oil drive shaft transmission if and 8 11 3 defective sealing ring defective Check carbon see chapters 8 11 1 brushes for oil 8 11 3 and 8 11 4 wetting replace motor if brushes wet Irregular None Drive shaft Check drive shaft
74. nting brackets 2 are affixed with screws to the top holes in the seat frame brackets 5 Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting brackets to 18 Nm When installing the cables again make sure that they are placed in such a way that they cannot be crushed or damaged in any position of the tilt module WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques Install the seat Install all covers again Check all functions of the vehicle and go for a test drive 111 SERVICE MANUAL Invacare FDX Series 8 13 2 3 Replacing the tilt actuator 112 Note This chapter only describes how to replace the tilt actuator To replace the complete tilt module please proceed as described in chapters 8 13 2 1 and 8 13 2 2 WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Use proper lifting techniques e Carefully secure the seat before removing the actuator Requirements Spring ring pliers e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cables and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstal
75. nual in the download area on htto www dynamiccontrols com Note When an electrical adjustment option is retrofitted such as electrical legrests then this option needs to be activated in the driving program as well if you have an ACS2 remote For more information refer to the user manual of the Wizard software and the installation instructions for the electronic modules 49 SERVICE MANUAL Invacare FDX Series 8 4 8 4 1 A Gor gt W 50 Batteries cables amp battery chargers Removing the batteries CAUTION Danger of injury and danger of damage to property if the batteries are handled incorrectly e The installation of new batteries may only be performed by authorised technicians e Pay attention to the warning notes on the batteries e Only use the battery type defined in the technical specifications CAUTION Risk of fire and burns if battery terminals are short circuited e Take special care that the battery terminals are NOT short circuited with a tool or metallic components of the wheelchair e Make sure that the battery terminal caps are fitted to the battery terminals at all times if you are not working on them CAUTION Danger of crushing The batteries are very heavy There is a danger that you may injure your hands e Take into account the heavy weight of the batteries e Handle the batteries carefully WARNING Risk of chemical burns Danger of injury by leaking acid e Wear a
76. odule Invacare FDX Series SERVICE MANUAL 8 2 4 2 Profile selection with remote REM A or REM B e Plug the plug into the remote or the ACS2 controller e LEDs 1 and 4 blink e Use the bottom rocker switch 5 to select where the required controller profile is saved LED 1 remote LED 4 ACS2 control system e The relevant LED illuminates permanently the other LED is off e Press the Horn 2 and 3 buttons on the speed selection and hold them down for 3 seconds to confirm the selection e The system will switch itself off and restart automatically During the process the selected profile will be saved both in the remote and in the electronic module 47 SERVICE MANUAL Invacare FDX Series 8 2 4 3 Profile selection with remote REM 550 48 Plug the plug into the remote or the ACS2 controller The display 2 shows that you need to select a profile Use the bottom rocker switch 3 to select where the required controller profile is saved remote Il electronic module The display will show which profile you have selected Press the Horn 4 and 1 buttons on the speed selection and hold them down for 3 seconds to confirm the selection The system will switch itself off and restart automatically During the process the selected profile will be saved both in the remote and in the electronic module Invacare FDX Series SERVICE MANUAL 8 3 Updating the driving program
77. ommends always replacing both springs to ensure optimum performance of the wheelchair WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Requirements e 5mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the suspension e Lift the wheelchair on one side and place a 14 cm high wooden block underneath the battery compartment so that the drive wheel is off the ground and can rotate freely Use proper lifting techniques e Repeat this on the other side of the wheelchair e Remove the drive wheel as described in chapter 8 8 1 e Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Remove the drive wheel as described in chapter 8 8 1 e Use the 5 mm Allen key to loosen and remove both screws 3 e Remove the black plastic stop 1 e Push the rear wheel cantilever arm downwards Invacare FDX Series SERVICE MANUAL With a 12 5 x 2 25 inch wheel in conjunction with a hard spring there is a shim located on top of the spring During the next work procedure pay attention to this shim e Remove the spring 2 Installing the suspension e Assemble th
78. onal Velcro fasteners 80 Invacare FDX Series SERVICE MANUAL Prop up the wheelchair on multiple wooden blocks Use proper lifting techniques Use the 22 mm socket wrench to loosen and remove the self securing nut 2 Pull the wheel fork 4 downwards out of the rear wheel cantilever arm 1 Pay attention to the washers 3 soacer washers and the separable ball bearings not visible in the illustration Installing a wheel fork Assemble the parts in reverse order When installing the ball bearings make absolutely sure that the wide inner rings are visible on the outside Adjust the wheel fork as described in chapter 8 7 3 The last step is to test all functions of the vehicle 81 SERVICE MANUAL Invacare FDX Series 8 7 3 Adjusting the wheel fork A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques 1A Requirements 24 e 22 mm socket wrench e Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 e Pull the cover up in the rear and remove it The cover is held in place by additional Velcro fasteners 82 Invacare FDX Series SERVICE MANUAL e Tilt the wheelchair forward over the drive wheels until the anti tipper wheels prevent it from tipping any farther Use proper lifting techniques e Swivel the wheels 5 so that they point upward e Release the wheels so that they can s
79. or send the battery charger to Invacare Service for repair LEDs are burnt out Send the battery charger to Invacare Service for repair a internal fuse might be burnt Send the battery charger to Invacare Service for repair Fuse on mobility aid has burnt Check mobility aid fuses out See chapter 8 4 4 Battery charger not connected Ensure that the battery to mobility aid charger has been connected to the mobility aid No mains supply Check the mains supply with a voltmeter Defective mains supply cable Check the mains supply cable Replace damaged cables or send the battery charger to Invacare Service for repair Battery charger could be Use a battery charger which defective you know is working properly to charge the batteries Send the defective battery charger to Invacare Service for repair Battery voltage is too low to Replace the batteries See operate mobility aid chapter 8 4 1 31 SERVICE MANUAL Invacare FDX Series 7 Test procedures 7 1 Testing the motor VA Requirements EA e Phillips screwdriver size 2 e digital multimeter with resistance measurement e Remove the rear panel as described in Chapter 8 1 2 e Pull the motor plug 1 out of the electronic module e Connect the digital multimeter to the motor plug contacts 3 and measure the resistance between the contacts Note A resistance of between 0 5 and 5 ohms indicates a motor ready for operation A resistanc
80. or take a photograph with a digital camera e Disconnect the cable of the affected tail lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair 72 Invacare FDX Series SERVICE MANUAL e Remove both plastic covers 2 e Use an 8 mm socket wrench to loosen both nuts e Remove the nuts together with the washers e Pull the tail lamp 1 towards the rear and remove from the tail lamp bracket 3 Installing the tail lamp e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions 13 SERVICE MANUAL Invacare FDX Series 8 6 13 Replacing the complete tail lamp assembly conventional lighting system starting 08 2014 1A Requirements be e 8mm socket wrench Uninstalling the tail lamp e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected tail lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair 74 Invacare FDX Series SERVICE MANUAL e Remove both plastic covers 6 e Use an 8 mm socket wrench to loosen the four nuts e Remove the nuts together with the washers 4 e Pull off the rear light 6 to the rear
81. p all cables so that you can lift the seat off WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques e Loosen the four screws 1 that attach the seat to the tilt module using a 4 mm Allen key and a 13 mm open end wrench e Lift the seat up off of the lifter module tilt module Use proper lifting techniques Invacare FDX Series SERVICE MANUAL kL al ral k j a ae as a n L E ae eg h F a at kA l Par F T a wu oS T Ss f oy a A d wo y T Er Fi a ae j a j a ai i j ee af z oll hat i a a Nhe a ie Y B h as Fa a ae a 4 i Ps a mi a i s igy Q o Pan I Gi fi S o a 2 a a q Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws 3 on both sides of the wheelchair Remove the screws and the washers Lift the tilt module 1 up off of its brackets 2 If one of the seat tilt mounting brackets 2 are to be replaced Use the 6 mm Allen key to loosen both screws 4 on the corresponding side of the wheelchair Remove the screws and the washers Remove the tilt mounting bracket If one of the seat frame mounting brackets 5 are to be replaced Disassemble the seat frame mounting brackets as described in chapter 8 13 1 starting from the section header Uninstalling the seat frame Installing the tilt module Install the tilt module in rev
82. programme Note All electronic modules are supplied with a standard drive programme If you have performed customer specific modifications to the drive programme then these will need to be recreated manually after installing the new electronic module Requirements e mm socket wrench e 3 mm socket wrench e To modify a drive programme you will need Programming software or a hand held programming device and the installation manual available from Invacare 41 SERVICE MANUAL Invacare FDX Series Uninstalling electronic modules e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e The illustration shows the electronic module 1 and the optional actuator module 2 The optional lighting circuit board is not shown in the picture but it would be installed at position 3 if it was present e Disconnect the plugs 1 from the electronic module and if installed from the optional actuator module and the optional lighting circuit board 42 Invacare FDX Series SERVICE MANUAL Use the 8 mm socket wrench to loosen and remove the nuts 1 Remove the actuator module together with the mounting plate 2 If the actuator module is to be replaced Use the 7 mm socket wrench and a Phillips screwdriver to loosen and remove the nuts 3 If th
83. r 2 e Remove the covers on the washer recesses 5 e Arrange the handlebar 1 on the back section in such a way that the boreholes coincide with the tapped holes in the back section e Fit the four Allen screws 4 incl the washers 5 and tighten the screws e Refit the plastic cover e Refit the six Allen screws 3 and tighten them 146 Invacare FDX Series SERVICE MANUAL 8 16 7 Replacing the travelling armrest VV Requirements E e 4mm Allen key Dismantling the travelling armrest e Undo and remove the four Allen screws in the backrest plastic cover using a 4 mm Allen key e Remove the plastic cover e f necessary remove the remote together with its cable e On the torque support loosen the locating pin 3 bolt 2 with a 4 mm Allen key e Raise the armrest slightly and remove the locating pin e Pull the armrest out of the torque support to the side If you raise and lower the armrest a few times it is easier to remove e Replace the armrest Refitting the travelling armrest e Replace the parts in the reverse order e To complete check all vehicle functions The new armrest will need to be adjusted to suit the user Please refer to the mobility device operating manual for detailed information 147 SERVICE MANUAL Invacare FDX Series 8 16 8 Replacing the arm support on the travelling armrest VA Requirements My e 4mm Allen key Dismantling the arm support e f necessary remove the
84. raised e Test the maximum speed reduction for correct function after any maintenance work or modifications to the wheelchair Component Check for Measures Remarks restraining belt damaged replace it buckle damaged replace it e Damage to the e Ifthe arm pad is armrests oe replace e Fixation of the E screws ae armrests i e Damage to the side e Replace the side the side parts Electric e Damage to the e Replace parts if backrest if DACKIESI damaged available Seams Tighten screws Fastening Replace cable or Check cable motor if necessary Check function Frame chassis Check fastenings Tighten screws battery welding seams and Replace parts if battery box necessary compartment wheel hubs and 8 8 3 s Restraining belt evenenelonand drive wheels and p axial run out ange e Check tight fit of e Replace wheels See chapter 8 7 steering wheels wheel fork or Check required wheel bearing motor to body clearance and axial run out e Tyres o replace See See chapter 8 8 2 if o e Check suspension e Repair or replace See chapter 8 9 ee if damaged e Check directional e Replace wheels See chapter 8 7 Stability wheel fork or and 8 8 wheel bearing 21 SERVICE MANUAL Invacare FDX Series Component Check for Measures Remarks a oD space ae e Check functions e Check the carbon See chapter 8 11 1 during drive brushes replace if ang 8 11 4 operation and when necessary
85. rear wheel cantilever arm off of the pivot point Assembling the motor gearbox fixation and rear wheel cantilever arm e Assemble the parts in reverse order e Tighten the self locking nut 2 hand tight and check the whole assembly moves freely 101 SERVICE MANUAL Invacare FDX Series 8 13 Seat adjustment standard 8 13 1 Seat seat frame without lifter 0 A Vd il 102 Note This chapter describes how to replace the seat frame on a wheelchair without a lifter or tilt module To replace a lifter or tilt module please follow the procedures explained in chapter 8 13 2 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Use proper lifting techniques Requirements 6 mm Allen key Torque wrench 5 30 Nm or similar Protractor Side cutting pliers Cable ties Wooden block Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Removing the seat e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 eS E US i e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera
86. ro 135 SERVICE MANUAL Invacare FDX Series 8 15 3 Replacing the EasyAdapt back Ni Requirements EA e 5mm Allen key e Oblique pliers e Cable ties we rad ge Dismantling the back unit e Remove the back cushion e Pull the actuator cable out of the actuator module under the seat e Pull the cable out of the mobility aid Remove any cable ties which are fitted e Loosen and remove the Allen screws 5 incl the washers on the left and right side of the seat e Carefully remove the back section 1 together with the lower part 2 from the seat support 3 The two parts are interconnected via the arm 4 Refitting the back unit e Refit the parts in reverse order e To conclude check all the mobility aid functions 136 Invacare FDX Series SERVICE MANUAL 8 15 4 Replacing adjusting the universal backrest frame for the EasyAdapt backrest Nii Requirements sia Measuring tape Adhesive tape 13 mm open end wrench 4 mm Allen key 5 mm Allen key Phillips screwdriver size 2 Uninstalling the universal backrest frame u i m me os i lt e Remove the backrest cushion e Loosen and remove the four Allen screws 1 with a 5 mm Allen key e Remove the universal backrest frame 2 from the EasyAdapt backrest 137 SERVICE MANUAL Invacare FDX Series Installing and adjusting the universal backrest frame AN CAUTION The upholstery may get damaged e When adjusting the backres
87. rs e Cable ties Uninstalling head lamps e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected head lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair e Loosen the hexagon socket head screw 1 with a 3 mm Allen key and remove the head lamp from the bracket e Replace the head lamp 64 Invacare FDX Series SERVICE MANUAL Installing head lamps e Assemble all parts again in reverse order e Install the cables carefully and secure them with cable ties Make sure that the cables not are not pinched or stretched e Tighten both screws hand tight e Check all vehicle functions e Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 65 SERVICE MANUAL Invacare FDX Series 8 6 6 Replacing headlamps completely LED lighting system starting 03 2012 VA Requirements EAF e 4mm Allen wrench e Side cutting pliers e Cable ties Uninstalling headlights e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets that they are connected to Mark the
88. rs stop and start irregularly Motor runs but loses power OTHER POSSIBLE SOLUTION SYMPTOMS CAUSE SERVICE MANUAL DOCUMENTATION Drive motors disengaged Engage drive motors See operating manual Batteries Replace batteries See chapter 8 4 1 defective Completely Pre charge batteries Check master see chapter 8 4 4 fuse Check cables see chapter 8 4 5 between the modules for loose connections and damage Remote Replace remote see chapter 8 2 1 defective Various causes Assess error code See chapter 6 2 See operating discharge manual battery Power supply to remote interrupted Batteries defective unstable voltage Replace batteries See chapter 8 4 1 Replace motor s See chapter 8 11 1 Replace carbon see chapter 8 11 4 brushes Change See chapter 8 3 programming to see chapter 8 4 5 Drive motor s defective Drive motors running asymmetrically synchronise motors Check all connecting cables Bad connections Measure internal resistance of brakes replace motor if defective Motor brake defective see chapters 7 2 and 8 11 1 25 Voltage decline Stop journey and allow electronic to cool down None High motor Stop journey and loading causes allow electronic to SERVICE MANUAL Invacare FDX Series PROBLEM OTHER POSSIBLE SYMPTOMS CAUSE electronic module to
89. ry 24V 2 Bus cable to remote or ACT a _ a 3 Bus cable to remote or ACT e Th 4 Motor M1 i Coy fir ON is mt i 5 Light f 6 Motor M2 Rubber stoppers for free slots e 2 amp 3 Order number 1552876 4 2 2 ACS2 PMAQOL electronic module 4 2 3 4 2 3 1 Connections 1 Battery 24V Cable to G Trac sensor GYRO eS a ro _ _ Bus cable to remote or ACT p T E Motor M1 la Light Motor M2 N N NSI SMa NM 2 3 4 5 6 Actuator module ACT Various types of adjustment motors also called actuators can be installed on the wheelchair These actuators are either connected directly to the electronic module or to a separate actuator module The actuator module is connected to the electronic module via a bus cable Actuator module ACT 2 Connections 1 ACI Bus cable to remote or ACT Bus cable to remote or ACT Adjustment motor actuator channel 2 2 3 4 5 Adjustment motor actuator channel 1 Rubber stoppers for free slots 1 Order number 1555701 2 amp 3 Order number 1552876 4 amp 5 Order number 1555700 The ACI connection serves to limit the movement of an actuator or to reduce velocity 17 SERVICE MANUAL 4 2 3 2 Actuator module ACT 4 Connections 1 ACI 2 Bus cable to remote or electronic module 3 Bus cable to remote or electronic module Actuator channel 4 Actuator channel 3 Actuator channel 2 4 5 6 7 Ac
90. s Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels VA Requirements HU 5 mm Allen key 10 mm socket wrench 13 mm socket wrench Torque wrench 0 10 Nm or similar Torque wrench 5 30 Nm or similar Torque wrench 10 80 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the motor gear box unit e Remove the drive wheel as described in chapter 8 8 1 e Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Disconnect the motor cable plug e Remove the wheel hub as described in chapter 8 8 3 A CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight 91 SERVICE MANUAL Invacare FDX Series 92 Use the 13 mm socket wrench to loosen the four screws 1 Hold the motor gearbox unit with one hand Completely remove the four screws including the washers Remove the motor gearbox unit Installing the motor gearbox unit Replace the defective components Before installing a new motor gearbox unit make sure the sealing ring 2 is correctly mounted The sealing ring securely attaches the motor 3 and the gearbox 5 The ring must be installed such that the self locking n
91. screws 8 on the rear side of the seat support connecting this to the cross braces 4 Unlike the dismantling of the old plates other holes of the three pairs of holes may possibly have to be used for the screws e Fit the two Allen screws 9 at the front of the seat support plate e Refit all parts that were removed 125 SERVICE MANUAL Invacare FDX Series 8 14 Centre mounted legrest electric amp manual Note The centre mounted legrest is the only part of the wheelchair in which screw sizes are indicated in inches 8 14 1 Replacing the manually operated centre mounted legrest A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight Ni Requirements EA e 5mm Allen key e 6mm Allen key e Side cutting pliers e Cable ties Uninstalling the manually operated centre mounted legrest F An electric legrest can be seen in the illustration The method of fixation to the seat is identical with both legrests e Uninstall the locking lever for the height adjustment of the legrest by loosening the grub screws with a 5 mm Allen key e Use the 6 mm Allen key to loosen and remove the two hexagon socket head screws 2 on both sides of the wheelchair e Completely remove both hexagon socket head screws including the washers e Pull the entire legrest forwards out of the seat e Loosen both hexagon socket head screws which attach the adap
92. seat VV Requirements EU e 5mm Allen key e Loosen the screw 1 with a 5 mm Allen key e Remove the screw 1 the washer 2 the seat belt the sliding bushing 3 and the sliding block 4 from the seat frame profile 5 e Replace the safety belt e Refit the parts in the reverse order 176 Invacare FDX Series SERVICE MANUAL 9 3 4 Replacing the harness belt adjustable seat V7 Requirements U e 13mm socket wrench e 5mm Allen key Uninstalling the harness belt e Remove the protective cap 2 e Loosen and remove the screw 6 the associated washers 5 and the nuts 4 in front of the behind the gripper clamp 3 with a 5 mm Allen key and a 13 mm socket wrench e Loosen and remove the screw 9 the associated washer 8 and the belt winder 7 in the lower part of the harness belt 1 with a 5 mm Allen key 177 SERVICE MANUAL Invacare FDX Series Note GD A belt winder is mounted so that the belt bracket can move freely e Replace the harness belt 1 Installing the harness belt e Assemble the parts in reverse order 178 Invacare FDX Series SERVICE MANUAL 9 3 5 Replacing the harness belt simple seat V7 Requirements U e 13 mm socket wrench e 5mm Allen key amp e T va Uninstalling the harness belt e Remove the protective cap 2 e Loosen and remove the screw 6 the associated washers 5 and the nuts 4 in front of the behind the gripper
93. st e Remove both adapter brackets Installing the electrically operated centre mounted legrest e Assemble the parts in reverse order e Testall functions of the wheelchair Invacare FDX Series SERVICE MANUAL 8 14 3 Replacing the electrically operated centre mounted legrest LNX Modulite seat A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight Nii Requirements d e 4mm Allen key e 10mm ring spanner or jaw spanner Uninstalling the electrically operated centre mounted legrest LNX e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Pull the plug of the legrest actuator out of the actuator module Loosen the screws 3 with a6 mm Allen key Pull the entire legrest 2 forwards out of the seat frame profile Loosen and remove the screws 1 including the nuts and washers with a 4 mm Allen key and a 10mm ring spanner or jaw spanner e Replace the legrest 2 129 SERVICE MANUAL Invacare FDX Series Installing the electrically operated centre mounted legrest LNX e Assemble the parts in reverse order e Testall functions of the wheelchair 8 14 4 Replacing an electric legrest actuator WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay a
94. st to be checked and not replaced then you must take note of the position and orientation of the brushes Used carbon brushes must be reinstalled in exactly the same position and orientation as they are in before to ensure optimum contact with the collector e Mark the motor and the carbon brush to ensure correct installation e Completely remove the carbon brush from the socket 2 e Check the carbon brush and the tension spring for wear broken pieces and discolouration Installing carbon brushes e Depending on the condition of the carbon brush and the tension spring Reinstall the same carbon brush exactly as it was before or Install a new carbon brush e Reposition the plastic caps and tighten them e Turn the motor into position so that the clutch lever or clutch rotary knob from 08 2014 can be set either to the push or drive position e Now retighten the bolt fingertight e Install the drive wheels as described in chapter 8 8 1 e Run the motor in as described in chapter 8 11 6 97 SERVICE MANUAL Invacare FDX Series 8 11 5 Fitting the clutch rotary knob SSD motor Note When replacing the clutch rotary knob you must ensure that the correct fitting position is used during assembly AS Requirements IV e 3 mm Allen key e Screw the shim on to the grub screw 0 e Place the screw joint in the rotary knob ee rear side 1 e e Check to ensure that the screw joint 4 is posi
95. t forget the spacer sleeve 2 e Install the washer and the self locking nut e Do not tighten the self locking nut completely as the motor orientation must be adjusted during installation e Install the motor gearbox unit as described in chapter 8 11 1 95 SERVICE MANUAL Invacare FDX Series 8 11 4 Replacing the carbon brushes Note i Always replace all carbon brushes on both motors at the same time A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet Use proper lifting techniques Nil Requirements yg Flat screwdriver 10 mm socket wrench Torque wrench 5 30 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling carbon brushes 96 Switch the wheelchair off Remove the drive wheels as described in chapter 8 8 1 Disconnect the motor 3 by setting the clutch lever or the clutch rotary knob from 08 2014 to push Loosen and remove the self locking nut 4 of the retaining ring 2 with a 10 mm socket wrench so that the motor 3 can be rotated against the gearbox 1 This way the carbon brushes are easier to access Invacare FDX Series SERVICE MANUAL e Loosen all four plastic caps 3 with a flat screwdriver and remove the caps e Pull the carbon brushes 4 out of their holders slightly Take note of the installation position and orientation of the carbon brushes Note If the carbon brushes are ju
96. t frame make sure the upholstery cannot collide with other components AA aW A 1 LA e Position both of the protective caps 8 in the lower ends of the lateral tubes 1 e Mark the center of the middle tube 2 with a piece of adhesive tape e Insert the middle tube into the upper ends of the lateral tubes e Position the lateral tubes of the EasyAdapt backrest so that the four Allen screws 7 can be screwed into the slot nuts 6 through the oblong holes Tighten the Allen screws just tight enough that the lateral tubes can slide and be adjusted without difficulty e Adjust the distance between the lateral tubes to the desired value using the measuring tape Make sure both lateral tubes are at an equal distance to the center of the seat e Tighten the four Allen screws 7 using a5 mm Allen key e Adjust the middle tube 2 so it is well centered e Screw both of the threaded pins 5 into the threaded holes 3 with a 4 mm Allen key e Secure the threaded pins additionally with the counter nuts 4 Tighten the counter nuts hand tight with a 13 mm open end wrench 138 Invacare FDX Series SERVICE MANUAL e Screw the four Phillips screws 9 into the drill holes provided for this purpose on the backs of the tubes The screws serve as limiters and prevent the backrest from sliding down too far e Remove the marking from the middle tube 139 SERVICE MANUAL Invacare FDX Series 8 16 Back unit with ergonomic
97. tely conventional lighting system starting 03 2012 Ni Requirements a e Phillips screwdriver size 2 Open end wrench 8 mm Side cutting pliers Cable ties Uninstalling headlights e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected headlight from the lighting circuit board e Open the cable clamps 1 remove all cable ties and pull the cable out of the wheelchair 62 Invacare FDX Series SERVICE MANUAL Loosen both of the nuts 1 with an 8 mm open end wrench and remove the headlight with the bracket from the rubber mounting Loosen both Phillips head screws 2 to remove the headlight from the bracket Replace the headlight Installing headlights Assemble all parts again in reverse order Install the cables carefully and secure them with the cable clamps and cable ties Tighten the screws hand tight Check all vehikel functions Perform an approximate adjustment of the headlight using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 63 SERVICE MANUAL Invacare FDX Series 8 6 5 Replacing the head lamps completely LED lighting system until 03 2012 VA Requirements a e 3mm Allen key e Side cutting plie
98. ter brackets 1 to the legrest e Remove both adapter brackets Installing the manually operated centre mounted legrest e Assemble the parts in reverse order e Testall functions of the wheelchair 126 Invacare FDX Series SERVICE MANUAL 8 14 2 Replacing the electrically operated centre mounted legrest A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight Ni Requirements EA e 6mm Allen key e Side cutting pliers e Cable ties Uninstalling the electrically operated centre mounted legrest e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Pull the plug of the legrest actuator out of the actuator module 127 SERVICE MANUAL Invacare FDX Series 128 e Use the 6 mm Allen key to loosen and remove the two hexagon socket head screws 2 on both sides of the wheelchair e Completely remove both hexagon socket head screws including the washers e Pull the entire legrest forwards out of the seat e Loosen both hexagon socket head screws which attach the adapter brackets 1 to the legre
99. th Phillips screws A on the middle plate 1 2 e Shift the position of the rear plate halves three settings are possible using the drill holes Before pulling the Flex3 backrest apart a 1 will be visible in the small rectangular cut out After pulling the Flex3 backrest apart a 2 will be visible in the small rectangular cut out e Re insert the two screws A into the middle plate e Fasten the front lateral plates 2 and 4 again 168 Invacare FDX Series SERVICE MANUAL 8 19 Fixation rings 8 19 1 Replacing a front fixation ring UA Requirements EAF e 13 mm socket wrenches two of them e Torque wrench 0 30 Nm or similar Removing a front fixation ring e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Remove the seat as described in chapter 8 13 or 8 17 e Loosen and remove both of the self locking nuts 3 e Pull the fixation ring 2 up and off of the seat frame 1 Installing a front fixation ring e Assemble all parts in reverse order e Tighten the screws 3 to a torque of 25 Nm e When installing the seat pay attention to its heavy weight e When installing the seat pay attention to the adjustment settings of the seat tilt e Check all functions of the vehicle and go for a test drive 169 SERVICE MANUAL Invacare FDX Series 8 19 2 Replacing a rear fixation ring VA Requirements HM e
100. the two upper front Allen screws 9 on the seat mounting plate and remove them e Loosen the four Allen screws at the front 7 and at the rear 8 that can be found on the side of the seat mounting plate in order to release tension and facilitate moving the plates Do not remove these screws entirely 120 Invacare FDX Series SERVICE MANUAL e Pull or push the seat mounting plate 2 to the desired width A scale 3 is included on the lower part of the seat support You can read off the seat width in centimetres on the scale e Repeat these work steps on the other side of the seat e Now tighten all the screws again 121 SERVICE MANUAL Invacare FDX Series 8 13 3 2 Adjusting the seat depth il Wg 122 Note The seat depth can be adjusted in stages between 38 and 53 cm Please also observe preceding chapter 8 13 3 1 on adjusting the seat width Requirements e 4mm Allen key e 38mm jaw spanner e Oblique pliers e Cable ties Note Certain holes in the seat support must be used for the screws depending on the desired seat depth It may possibly be necessary to replace the seat support plates e Use the following illustration and the table to determine which holes must be used for the desired seat depth and whether the seat support plates possibly have to be replaced Sepa ric Seat frame front 1524550 2 e920 6 A Seat frame rear Invacare FDX Series SER
101. tion to the seat is almost identical with both legrests Uninstalling the calf plate e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Use the 1 64 Allen key to loosen and remove both screws 2 e Remove the calf plate 1 Installing the calf plate e Assemble the parts in reverse order e Using the different adjustment holes 3 in the calf plate and in the calf plate brackets the calf plates can be mounted at different heights and widths This must be adjusted to fit the needs of the user Invacare FDX Series SERVICE MANUAL 8 14 6 Replacing the foot plate on the centre mounted legrest electric amp manual VA Requirements dd e 1 64 Allen key e 1 4 Allen key A manual legrest can be seen in the illustration The method of fixation to the seat is almost identical with both legrests Uninstalling the footplate e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Use the 1 64 Allen key to loosen and remove both screws 3 e Replace the foot plate 1 Installing the footplate e Assemble the parts in reverse order e Tighten the hexagon socket head screws 3 till they are tight enough that the footplate can barely be moved
102. tioned precisely in the rotary Knob e Place the nonwoven fabric 3 in the rotary knob rear side 1 e When installing the rotary knob 5 ensure that the position 6 is correct e Tighten the bolt using a 3 mm Allen key e Checked to ensure that the clutch rotary knob can be turned to the push position downloads and drive upwards 98 Invacare FDX Series SERVICE MANUAL 8 11 6 Running the motor in Note The following procedure is necessary to run in the motor after replacing the carbon brushes to guarantee maximum performance WARNING Danger of accidents Danger to people the surroundings and wheelchair e Never leave the wheelchair unattended during the following procedure e Make sure that BOTH drive wheels are raised and CANNOT touch the ground e Secure the surrounding area Nii Requirements ad e Two oblong wooden blocks at least 14 x 14 x 30 cm e Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely Use proper lifting techniques e Repeat this on the other side of the wheelchair e Allow the motors to run for an hour in the forward direction e Allow the motors to cool off for 30 minutes e Allow the motors to run for an hour in the backward direction e Lift the wheelchair off of the wooden blocks 99 SERVICE MANUAL Invacare FDX Series 8 12 Replacing the motor gearbox fixatio
103. tions and tables Seat frame Screw position Seat width B 480mm__ PD 880mm Leg supports connection Screw position _ Seat width _ B 480mm D 530mm Note When switching from 430 mm to 480 mm and the other way around the fixation of the legrests must be replaced e Reposition the screws and tighten them again Install the seat plate or the sling seat Reposition the seat cushion 1 m 163 SERVICE MANUAL Invacare FDX Series 8 18 4 2 Adjusting the seat width legrest LNX Wd 164 You can only adjust the seat width for the adjustable seat plate or for the adjustable sling seat At the legrest LNX the seat width is adjusted with the seat frame The sling seat is available in two widths for a seat width of 38 43 cm and for a seat width of 48 53 cm When modifying the seat width the backrest width must also be correspondingly adapted See chapter 8 18 4 3 Requirements 3 mm Allen key 5mm Allen key 13 mm open ended spanner T25 Torx wrench T40 Torx wrench 4 mm Allen key legrest LNX 10 mm ring spanner or jaw spanner legrest LNX Remove the backrest cushion Remove the backrest from the backrest mounting bracket see chapter 8 18 Loosen and remove the screws which secure the middle seat plate A with a 3 mm Allen key Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral seat plates C
104. ttention to the heavy weight Nii Requirements Y 1 2 socket wrench 3 8 Allen key Side cutting pliers Cable ties hy Uninstalling the electrically operated legrest e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Pull the plug of the legrest actuator out of the actuator module 130 Invacare FDX Series SERVICE MANUAL e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 3 e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 1 e Remove the nuts including the washers but leave the screw inserted in the screw hole do not pull it completely out e Pull the actuator 2 toward the side off of the screws 1 and 3 e Replace the actuator Installing the electrically operated legrest e Assemble the parts in reverse order e Testall functions of the wheelchair 131 SERVICE MANUAL Invacare FDX Series 8 14 5 Replacing the calf plate on the centre mounted legrest electric amp manual Wi 132 Requirements e 1 64 Allen key fy A manual legrest can be seen in the illustration The method of fixa
105. ttery cables Installing batteries battery cables e Assemble the parts in reverse order Connect the negative terminal first then the positive terminal e Make sure the battery box sockets and plugs are correctly installed A schematic showing the correct positions can be found in the battery box cover e Carefully reposition the battery terminal caps and secure them with a cable tie to prevent them from possibly slipping out of place Invacare FDX Series SERVICE MANUAL How to handle damaged batteries correctly WARNING Risk of chemical burns Danger of injury by leaking acid e Wear acid resistant protective gloves when handling batteries e Wear protective goggles when handling batteries How to deal with a battery acid leak e Remove clothes that have been soiled or soaked with acid immediately e mmediately wash the affected area of skin that has come into contact with battery acid with lots of water After contact with eyes e Immediately rinse eyes under running water for several minutes Consult an eye doctor immediately afterwards Requirements e Safety goggles e Acid resistant gloves e Acid resistant container for transportation e Always wear appropriate safety clothing when handling damaged batteries e Place damaged batteries in an acid resistant container immediately after removing them e Only ever transport damaged batteries in an appropriate acid resistant container e Wash all objects that
106. tuator channel 1 Rubber stoppers for free slots 1 Order number 1555701 2 amp 3 Order number 1552876 4 to 7 Order number 1555700 Invacare FDX Series T The ACI connection serves to limit the movement of an actuator or to reduce velocity 4 2 4 Lighting circuit board The connections of the lighting circuit board are located directly on the board Invacare FDX Series SERVICE MANUAL 4 3 Remotes Various types of remotes can be installed on the wheelchair Before you connect componenis of the wheelchair such as adjustment motors or actuators make sure you know exactly which remote is installed The following table provides an overview pro peos e REM G90A Can be connected to ACS2 PMB70 ACS2 PMB70L ACS PMA90LG power modules Can be connected to ACS2 PMB70 ACS2 PMB70L ACS PMA90LG power modules 19 20 SERVICE MANUAL Remotes REM 550 Invacare FDX Series an a eee Can be connected to ACS2 PMB70 ACS2 PMB70L ACS PMA90LG power modules Can be connected to ACS2 PMB70 ACS2 PMB70L ACS PMA90LG power modules Invacare FDX Series SERVICE MANUAL 5 A Maintenance plan once a year CAUTION Danger of injury and damage to property if the maximum speed reduction on a wheelchair with a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is
107. ule but not the other way around Invacare FDX Series SERVICE MANUAL 8 Repair Work A CAUTION Danger of injury and damage to property if the maximum speed reduction on a wheelchair with a lifter does not function correctly e The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is raised e Test the maximum speed reduction for correct function after any maintenance work or modifications to the wheelchair 8 1 Covers 8 1 1 Open front cover Removing the front cover e Remove the leg rests e Loosen and remove both of the knurled head screws 1 e Press the front cover 2 slightly upward then pull the cover forward and off Installing the front cover e Assemble the parts in reverse order e When installing the plastic cover make sure that the slots on the sides 3 and the lower hooks on the cover latch onto the chassis 4 e Tighten both knurled head screws hand tight 35 36 SERVICE MANUAL 8 1 2 Opening the rear cover Invacare FDX Series Removing the rear cover e Loosen and remove both of the knurled head screws 1 e Remove the rear cover 2 Installing the rear cover e Assemble the parts in reverse order Tighten both knurled head screws hand tight Invacare FDX Series SERVICE MANUAL 8 1 3 Opening the lateral cover VA Requirements EA e 10mm socket wrench e 6mm Allen key e Two oblong wooden blocks at least 14 x 14
108. ut 4 is located on the outside If the sealing ring is incorrectly installed rotate it around as described in chapter 8 11 2 Refit the motor transmission unit in reverse order Use the scale to align the motor to the centre axis 1 2 pole motors and 4 pole motors Left 0 Right 0 z Make sure that the motor cable cannot be pinched or bent and i 1 that it is not exposed to chafing in any place ee PHI To conclude you should always carry out a trial run to test the vehicle functions Invacare FDX Series SERVICE MANUAL 8 11 2 Replacing or rotating the motor gearbox unit sealing ring A Li CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight Requirements e 10mm socket wrench Uninstalling the sealing ring Uninstall the motor gearbox unit as described in chapter 8 11 1 Use the 10 mm socket wrench to loosen and remove the self securing nuts 4 including the washers Remove the carriage bolt which secures the sealing ring 2 Carefully bend the sealing ring apart and remove it Installing the sealing ring Install the sealing ring so that the square hole for the carriage bolt is on the inside of the wheelchair Insert the carriage bolt through the sealing ring Install the washer and the self locking nut Do not tighten the self locking nut completely as the motor orientation must be
109. wheel a Ta l W Om i p e Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the rear wheel is off the ground and can rotate freely Use proper lifting techniques e Carefully remove the black plastic cap from the middle of the anti tipper wheel 1 with a small flat screwdriver The cap is not shown in the above illustration e Use the 16 mm socket wrench to loosen the self securing axle nut 2 e Remove the axle nut and the washer e Pull the wheel off the axle Installing a rear wheel e Assemble the parts in reverse order e Tighten the self securing axle nuts just tight enough that the wheel can still rotate without resistance 79 SERVICE MANUAL Invacare FDX Series 8 7 2 Replacing a rear wheel fork A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Vil Requirements 24 e 22mm socket wrench e 4mm Allen key e Oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling a wheel fork e Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 e Pull the cover up in the rear and remove it The cover is held in place by additi
110. wheel in reverse order e Tighten the screws to a torque of 25 Nm Invacare FDX Series SERVICE MANUAL 8 8 2 Replacing a tyre Wi a fi Requirements 5 mm Allen key Two oblong wooden blocks at least 14 x 14 x 30 cm Three c clamps with plastic caps Torque wrench 5 30 Nm or similar Talcum powder Uninstalling a tyre Remove the wheel as described in chapter 8 8 1 CAUTION EXPLOSION HAZARD The tyre is under high pressure There is danger of injury Parts can be projected at you causing serious injury if you do not secure the wheel rims e Secure the wheel rim halves with c clamps Secure the wheel rim halves with three c clamps to prevent them from unintentionally popping apart Be careful not to scratch the rims in the process Loosen the five 5 mm hexagon socket head screws 2 on the inside of the wheel Carefully loosen the c clamps in small increments one after the other until you can safely remove the rim halves Remove the inner ring 3 and outer ring 1 of the rim from the tyre 4 Replace defective or worn out components Installing a tyre Assemble the tyre in reverse order on the rim When assembling the rim halves make sure that the smooth and threaded holes for the screws are aligned exactly on top of each other Apply the three c clamps Tighten the c clamps in small increments one after the other until the rim halves are squarely pressed together Tighten the hexago
111. wing downwards e Adjust the nut 2 using a 22 mm socket wrench so that the wheel forks are not too loose but can still rotate freely The wheels should swing up to the other side a maximum of one time before coming to rest pointed downward e Place the wheelchair back on all of its wheels e Test the maneuverability of the wheelchair e Repeat the individual steps if necessary until the coasters are correctly adjusted e Install the cover again 83 84 SERVICE MANUAL Invacare FDX Series 8 8 Drive wheels 8 8 1 Replacing a drive wheel A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Nil Requirements E e 6mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm e Torque wrench 5 30 Nm or similar Uninstalling a drive wheel e Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely Use proper lifting techniques e Repeat this if necessary on the other side of the wheelchair e Loosen the five 6 mm hexagon socket head screws 1 e Pull the wheel 2 off the hub Installing a drive wheel e Install the
112. with a 3 mm Allen key Remove the lateral seat plates D or Remove the seat cushion Loosen and remove the screws on both sides which secure the sling seat A with a T25 Torx wrench Remove the sling seat B N PALES Invacare FDX Series With the legrest LNX the seat width is set directly via the seat frame because the LNX bracket is attached directly to the seat profile e To adjust the seat width loosen and remove the screws of the seat frame adjustment A with a T40 Torx wrench See table on p 163 e With the LNX bracket use the outer drill hole B to adjust the corresponding width for the legrest fixation LNX of the seat width SERVICE MANUAL e Loosen and remove the screws 3 include the washers 2 and the nut 1 on the left and right side e Adjust to the desired seat width e Reposition the screws and tighten them again e Install the seat plate or the sling seat e Reposition the seat cushion 165 SERVICE MANUAL Invacare FDX Series 8 18 4 3 Adjusting the backrest width The backrest width is adjusted by performing the following tasks e Adjust the backrest tube e Adjust the backrest Sling backrest as described in chapter 8 15 2 Flex3 backrest as described in chapter 8 18 4 4 e Replace the backrest cushion these are available in various widths When modifying the backrest width the seat width must also be correspondingly adapted Please see
113. wo cap nuts 2 using an 8 mm spanner and remove the headlight with the mounting from the rubber bumpers Replace the mounting Refitting the bulbholder Refit the parts in reverse order Now tighten all the screws finger tight again Check all vehicle functions Adjust the headlight roughly using the grid The user can carry out the final adjustment following the operating manual Invacare FDX Series SERVICE MANUAL 8 6 10 Replacing a light bulb in the rear conventional lighting system 1A Requirements ad e Phillips screwdriver size 2 e Loosen the Phillips head screw in the transparent cover of the tail lamp turn indicator combination e Remove the transparent plastic cover e Replace the defective light bulb e Reposition the cap and tighten the Phillips head screw hand tight 8 6 11 Replacing the LEDs in the rear LED lighting system e Individual LEDs are not intended to be replaced Replace the complete red tail lamp and or the yellow turn indicator as described in chapter 8 6 16 71 SERVICE MANUAL Invacare FDX Series 8 6 12 Replacing the complete tail lamp assembly conventional lighting system until 08 2014 1A Requirements be e 8mm socket wrench Uninstalling the tail lamp e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets
114. working with batteries e Wear safety gloves when this symbol is shown Note This symbol identifies general information which is intended to simplify working with your product and which refers to special functions Requirements e This symbol identifies a list of various tools components and items which you will need in order to carry out certain work Please do not attempt to carry out the work if you do not have the listed tools available Always dispose used or damaged batteries correctly The symbol refers to information for the correct disposal of used or damaged batteries Invacare FDX Series SERVICE MANUAL 1 5 Images in this manual The detailed images in this manual are given digits to identify various components Component numbers in text and operational instructions always relate to the image directly above 11 SERVICE MANUAL Invacare FDX Series 2 1 Safety and fitting instructions These safety instructions are intended to prevent accidents at work and it is imperative that they are observed Before any inspection or repair work e Read and observe this repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information Personal safety equipment Safety shoes The mobility device and some of its components are very heavy These parts can result in injuries to the feet if they are allowed to drop e Wear

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